Repair Procedures: Installation

Dowel pin of crankshaft set about 3° with vertical center line.

Fig 1: Crankshaft Dowel Pin Installation Position
Courtesy of KIA MOTORS AMERICA, INC.
Align the TDC marks (A) of the CVVT sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.

Fig 2: Locating TDC Marks Of CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Install the new O-rings (A).

Fig 3: Locating O-Rings
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A) and the timing chain (B).
Tightening Torque:

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

Fig 4: Locating Timing Chain Guide And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
Order: Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket.
Install the chain tensioner arm (A).
Tightening Torque:

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

Fig 5: Locating Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the hydraulic tensioner (A) and remove the pin (B).
Tightening Torque:

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

Fig 6: Locating Hydraulic Tensioner And Pin
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Recheck the top dead center (TDC) marks on the crankshaft and camshaft.
Install the timing chain cover.
1. Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
2. Apply the liquid gasket (TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.
  Width: 3 ~ 5 mm (0.1181~0.1969 in.)
3. Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts (A) of the timing chain cover and THREE BOND 1217H or LOCTITE 5900H on the rest parts (B). Reassemble the cover within 5 minutes.
  Width: 3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
  
  Fig 7: Locating Timing Chain Cover Liquid Gasket Applying Area
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: Remove oil or dust on the surface surely.
4. Align the dowel pin of the cylinder block and the holes of the oil pump.
5. Tighten the bolts to install the timing chain cover (A).
  Tightening Torque:
  
  M8 bolts:
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  M6 bolts:
  
  9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Fig 8: Locating Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: After the installation, do not crank engine or apply pressure on the cover for half an hour.
Using the SST (09455-21200), reassemble the timing chain cover oil seal.

Fig 9: Reassembling Timing Chain Cover Oil Seal Using SST (09455-21200)
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft pulley (A).
Tightening Torque:

11T: 127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lb-ft)

12T: 46.1 ~ 52.0 N.m (4.7 ~ 5.3 kgf.m, 34.0 ~ 38.3 lb-ft) + 38 ~ 42°

Fig 10: Locating Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 11: Crankshaft Pulley Bolts
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 12: Holding Ring Gear Using SST (09231-2B100)
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the bracket (A).
  
  Fig 13: Removing Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 14: Locating Dust Cover And Transaxle Mounting Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4. Adjust the angle of the links (D), and fasten the bolt 70 mm (2.7559 in) in the original mounted hole.
  
  Fig 15: Adjusting Length Of Holder Nuts
  Courtesy of KIA MOTORS AMERICA, INC.
5. Tighten the bolts and nuts of the holder and links securely.
Fig 16: Tightening Bolts And Nuts Of Holder And Links
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 17: Pulley Groove
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump (A) with a gasket.
Tightening Torque:

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

Fig 18: Locating Water Pump
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A) and the drive belt idler (B).
Tightening Torque:
1. 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
Fig 19: Installing Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tighten the bolts diagonally.
Install the engine support bracket (A).
Tightening Torque:

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
Install the alternator bracket (B).
Tightening Torque:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

Fig 20: Locating Alternator Bracket And Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting support bracket (B) and then connect the ground line (A).
Tightening Torque

Ground line bolt:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

Nut (C):

63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

Bolt (D) and nuts (E):

49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

Fig 21: Locating Engine Mounting Support Bracket And Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Install the alternator (A).
Tightening Torque:

M8 bolt:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

M10 bolt:

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)

Fig 22: Installing Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).

Fig 23: Locating Drive Belt
Courtesy of KIA MOTORS AMERICA, INC.
Adjust tension by tightening the Alternator Tension Adjust Bolt (A). (Refer to CHARGING SYSTEM ).
Tension

[With OAD]

New belt: 637.4 ~ 735.5N (65 ~ 75 kg, 143.3 ~ 165.3 lb)

Used belt: 490.3 ~ 588.4N (50 ~ 60 kg, 110.2 ~ 132.3 lb)

[Without OAD]

New belt: 882.6 ~ 980.7N (90 ~ 100 kg, 198.4 ~ 220.5 lb)

Used belt: 637.4 ~ 735.5N (65 ~ 75 kg, 143.3 ~ 165.3 lb)

Fig 24: Adjusting Tension
Courtesy of KIA MOTORS AMERICA, INC.
Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
After applying the liquid gasket, THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.
Width: 2.0 ~ 2.5 mm (0.0787~0.0984 in.)

Fig 25: Locating Liquid Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Install the OCV (Oil Control Valve) adapter (A).
Tightening Torque:

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

Fig 26: Installing OCV Adapter
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Keep the OCV adapter clean.
- Make sure the O-rings on the front bearing cap are installed.
Install the cylinder head cover (A) with a new gasket (B).

Fig 27: Locating Cylinder Head Cover And Gasket
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do Not reuse the disassembled gasket.
Tighten the cylinder head cover bolts with the order and steps.
Tightening Torque:

1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 28: Cylinder Head Cover Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Install the exhaust OCV (Oil Control Valve) (A).
Tightening Torque:

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

Fig 29: Installing Exhaust Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
Install the ignition coils (A).
Tightening Torque:

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

Fig 30: Installing Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to HIGH PRESSURE FUEL PUMP )
Tightening Torque:

12.7 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.8 lb-ft)

Fig 31: Installing High Pressure Fuel Pump And Roller Tappet
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

NOTE: Do not use already used bolt again.

NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.

CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

CAUTION: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

Fig 32: Locating O-Ring, Roller Tappet And Protrusion
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure pipe (A). (Refer to DELIVERY PIPE )
Tightening Torque:

25.5 ~ 31.4 N.m (2.6 ~ 3.2 kgf.m, 18.8 ~ 23.1 lb-ft)

Fig 33: Locating High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not reuse the high pressure pipe.
Install the vacuum pipe assembly (A).
Tightening Torque:

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

Fig 34: Locating Vacuum Pipe Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Connect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 35: Locating Fuel Hose And PCSV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the oxygen sensor connectors (A) and the condenser connector (B).

Fig 36: Locating Oxygen Sensor Connectors And Condenser Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).

Fig 37: Locating FPCV And Intake And Exhaust CMPS Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).

Fig 38: Locating Ignition Coil Connectors, Injector Extension Connector, VIS Connector And PCSV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).

Fig 39: Locating Intake And Exhaust Oil Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).
Tightening Torque:

9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

Fig 40: Locating A/C Compressor Switch Connector, Alternator Connector And Alternator Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Install the under covers (A).
Tightening Torque:

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

Fig 41: Installing Under Covers
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (D) and then connect the air intake hose (C).
  Tightening Torque:
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
2. Connect the breather hose (B).
3. Install the air duct (A).
Fig 42: Locating Air Cleaner Assembly, Air Intake Hose, Breather Hose And Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
- Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
Fig 43: Locating Hose Clamp Plate And Hose Stopper
Courtesy of KIA MOTORS AMERICA, INC.
Connect the battery negative terminal (A).
Tightening Torque:

Without battery sensor:

7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

With battery sensor:

4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)

Fig 44: Locating Battery Negative Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover.
CAUTION: Make sure the engine cover is installed before driving.