Repair Procedures: Installation

Install the timing chain cover (A).
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spray cleaner on the surface and wipe with a clean duster.
3. Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.
  Bead Width: 3.0 - 5.0 mm (0.11 - 0.20 in.)
  
  Sealant: Threebond 1217H or equivalent
  
  Fig 1: Installing Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the new O-ring (A).
  
  Fig 2: Installing O-Ring
  Courtesy of KIA MOTORS AMERICA, INC.
5. After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes of applying sealant. Continuous bead of sealant should be applied to prevent any path from oil leakage.
  Bead Width:
  
  Whole section: 2.5 - 3.5 mm (0.10 - 0.14 in.)
  
  Section: 3.5 - 4.5 mm (0.14 - 0.18 in.)
  
  Sealant: Threebond 1217H or equivalent
  
  Fig 3: Applying Liquid Sealant On Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
6. Install the timing chain cover. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference for assembling the timing chain cover to the exact position.
Tightening Torque:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

Fig 4: Installing Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: It is not recommended to start the engine or perform pressure test within 30 minutes of assembling the timing chain cover.
Install the variable force solenoid (VFS) valve (A).
Tightening Torque:

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

Fig 5: Installing Variable Force Solenoid (VFS) Valve
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Do Not use any dropped variable force solenoid (VFS) valve.
- Note below cautions when installing variable force solenoid (VFS) valve.
1. After replacing the O-ring (A) of variable force solenoid (VFS) valve, apply engine oil on new O-ring (A).
  
  Fig 6: Replacing O-Ring Of Variable Force Solenoid (VFS) Valve
  Courtesy of KIA MOTORS AMERICA, INC.
2. Push variable force solenoid (VFS) valve up to the timing chain cover, and temporarily tighten the bolt.
3. Tighten the variable force solenoid (VFS) valve to the specified torque.
Replace the front oil seal if necessary.
(Refer to Timing System - "FRONT OIL SEAL ")
Install the remaining parts in the reverse order of removal.
Connect the high voltage circuit.
(Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
Add all the necessary fluids and check for leaks. Connect KDS/GDS. Check for codes, note, and clear. Recheck.

NOTE:

Refill engine with engine oil.
Clean battery posts and cable terminals and assemble (12 Volt only).
Inspect for fuel leakage.

After assembling the fuel line, switch on the ignition (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, then check for fuel leakage at any point in the fuel line.