Repair Procedures: Installation

Check that the TDC marks on the intake and exhaust CVVT sprockets are slightly turned (about 1 to 2 teeth) from the TDC position after the timing chain has been removed.

Fig 1: Check TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Turn the crankshaft about 1 to 2 teeth clockwise from the TDC position (approx. 3° clockwise from the engine vertical line), by the same amount of rotation as the intake CVVT sprocket from the TDC position.

Fig 2: Turn Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening torque:

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 3: Install Timing Chain Guide Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening torque:

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 4: Install Timing Chain Tensioner Arm Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain.
Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket
1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
  
  Fig 5: Install Timing Chain
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.
2. Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.
Fig 6: Turn CVVT Assembly Clockwise
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- The timing mark of the exhaust CVVT sprocket should be matched with timing mark (color link) of timing chain when installing the timing chain.
- Press down the timing chain links on the exhaust CVVT sprocket to prevent the sprocket from spinning.
Install the timing chain auto tensioner (A) and remove the stopper pin (B).
Tightening Torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 7: Install Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- When installing the tensioner, check that the ratchet of the tensioner functions normally after removing the stopper pin by pushing the tensioner arm (A) as close to the tensioner as possible as shown below.
- When the tensioner plunger is retracted maximally, there should be no interference between the tensioner arm (A) and the tensioner housing (B).
Fig 8: Push Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks on the intake and exhaust CVVT sprockets are aligned with the top surface of cylinder head.

Fig 9: Check TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Install the other parts in reverse order of removal.
NOTE:
- Refill engine with engine oil.
- Clean battery posts and cable terminals and assemble.
- Inspect for fuel leakage.
  - After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.