Repair Procedures: Installation

The key (A) of crankshaft should be aligned with the timing mark (B) of block. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 1: Locating Crankshaft Key
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Install the tensioner adapter assembly (A).

Fig 2: Install Tensioner Adapter Assembly
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Install the crankshaft sprocket (A). (LH camshaft drive).

Fig 3: Install Crankshaft Sprocket (LH Camshaft Drive)
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Install the LH timing chain (A).

Fig 4: Install LH Timing Chain
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Fig 5: LH Timing Chain Mark
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NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below:
Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket → Intake camshaft sprocket.
When installing the timing chain, be sure that the timing mark of each sprocket is matched with the timing mark (color link) of the timing chain.
Install the LH timing chain guide (A).
Tightening torque :

19.6 - 24.5 N.m (2.0 - 2.5 kgf.m, 14.5 - 18.1 lb.ft)

Fig 6: Install LH Timing Chain Guide
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Install the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
Tightening torque
1. 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)
2. 18.6 - 21.6 N.m (1.9 - 2.2 kgf.m, 13.7 - 15.9 lb.ft)
Fig 7: Install LH Timing Chain Auto Tensioner & LH Timing Chain Tensioner Arm
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Install the LH timing chain cam to cam guide (A).
Tightening torque :

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

Fig 8: Install LH Timing Chain Cam To Cam Guide
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Pull out the pins of LH timing chain auto tensioner.

Fig 9: Pulling Out Pins Of LH Timing Chain Auto Tensioner
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Install the crankshaft sprocket (A) (Oil pump drive).

Fig 10: Install Crankshaft Sprocket (Oil Pump Drive)
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Install the oil pump chain sprocket (A) and oil pump chain (B).
Tightening torque :

18.6 - 21.6 N.m (1.9 - 2.2 kgf.m, 13.7 - 15.9 lb.ft)

Fig 11: Install Oil Pump Chain Sprocket And Oil Pump Chain
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Install the camshaft sprocket. (RH camshaft drive)

Fig 12: Install Camshaft Sprocket (RH Camshaft Drive)
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Install the RH timing chain (A).

Fig 13: InstallRH Timing Chain
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Fig 14: RH Timing Chain Mark
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NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below:
Crankshaft sprocket →Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
When installing the timing chain, be sure that the timing mark of each sprocket is matched with the timing mark (color link) of the timing chain.
Install the RH timing chain guide (A).
Tightening torque :
1. 19.6 - 24.5 N.m (2.0 - 2.5 kgf.m, 14.5 - 18.1 lb.ft)
Fig 15: Install RH Timing Chain Guide
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Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
Tightening torque
1. 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)
2. 18.6 - 21.6 N.m (1.9 - 2.2 kgf.m, 13.7 - 15.9 lb.ft)
Fig 16: Install RH Timing Chain Auto Tensioner & RH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain cam to cam guide (A).
Tightening torque :

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

Fig 17: Install RH Timing Chain Cam To Cam Guide
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Pull out the pins of RH timing chain auto tensioner.

Fig 18: Pull Out Pins Of RH Timing Chain Auto Tensioner
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Install the oil pump chain tensioner assembly (A).
Tightening torque :

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

Fig 19: Install Oil Pump Chain Tensioner Assembly
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After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
Turning the crankshaft counterclockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengagement from the sprocket teeth.
Install the timing chain cover.
(Refer to Timing System - "TIMING CHAIN COVER ")
Install the remaining 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.