Repair Procedures: Installation

Install the Timing Chain Cover.
1. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
2. Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.
  Bead Width: 2.5 mm (0.1 in.)
  
  Fig 1: Installing Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Apply Liquid Sealant TB 1217H on Timing Chain Cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity.
  
  Fig 2: Locating Dowel Pin
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Fill the T-Joint area (6EA *) with sealant.
  - Apply sealant all around the dowel pin hole (2EA).
    Information
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 3: Installing Gasket To Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: When installing the timing cover, take cautious not to take off applied sealant from the timing cover by contacting with other parts.
5. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
  Tightening Torque
  1. A (16EA):
    18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
  2. (2EA):
    24.5 ~ 26.5 N.m (2.5 ~ 2.7 kgf.m, 18.1 ~ 19.5 lb-ft)
  3. (2EA):
    58.8 ~ 68.8 N.m (6.0 ~ 7.0 kgf.m, 43.4 ~ 50.6 lb-ft)
  4. (3EA):
    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  Fig 4: Tightening Dowel Pins
  Courtesy of KIA MOTORS AMERICA, INC.
6. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the other parts in the reverse order of removal.
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
  - After assembling the fuel line, turn on the ignition switch (without operating the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two to three times, and then check for fuel leakage at any point on the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
  - Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
  - Turn off the engine and let it cool down. Check the level in the radiator, and add coolant if needed. This will allow trapped air to be released from the cooling system.
  - Put radiator cap on tightly, then run the engine again and check for leaks.