Repair Procedures: Installation

Install the jack to the edge of upper oil pan to support the engine.
NOTE: Insert the rubber block between jack and upper oil pan.
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 And Block Timing Mark
Courtesy of KIA MOTORS AMERICA, INC.
Install the tensioner adapter assembly (A).

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

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

Fig 4: Locating LH Timing Chain
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Fig 5: Timing Chain Installation Position
Courtesy of KIA MOTORS AMERICA, INC.

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

Fig 6: Locating LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
Tightening torque

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

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

Fig 7: Locating LH Timing Chain Auto Tensioner & LH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH timing chain cam to cam guide (A).
Tightening torque:

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

Fig 8: Locating LH Timing Chain Cam To Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Pull out the pins of LH timing chain auto tensioner.

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

Fig 10: Locating Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain sprocket (A) and oil pump chain (B).
Tightening torque:

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

Fig 11: Locating Oil Pump Chain Sprocket & Oil Pump Chain With Bolt
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Install the RH timing chain (A).

Fig 12: Locating RH Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.

Fig 13: RH Timing Chain Installation Position
Courtesy of KIA MOTORS AMERICA, INC.

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:

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

Fig 14: Locating RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
Tightening torque

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

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

Fig 15: Locating 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 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Fig 16: Locating RH Timing Chain Cam To Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Pull out the pins of RH timing chain auto tensioner.

Fig 17: Locating RH Timing Chain Auto Tensioner Pins
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain tensioner assembly (A).
Tightening torque:

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

Fig 18: Locating Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain cover (A).
Tightening torque:

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

Fig 19: Locating Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
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 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.