Repair Procedures: Installation

Install the timing chain cover.

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.

Before assembling the timing chain cover, apply the liquid sealant TB 1217H on the gap between cylinder head and cylinder block. Assemble the part within 5 minutes of applying sealant.

Bead width: 4.0 mm (0.2 in.)

Courtesy of KIA MOTORS AMERICA, INC.

Apply liquid sealant TB 1217H on timing chain cover. Assemble the part within 5 minutes of applying sealant.

Apply sealant in a continuous thread.

Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

Fill six (6) T-joint areas with sealant.
Apply sealant all around two (2) dowel pin holes.

Install the new gasket (A) to the timing chain cover.

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: During timing chain cover installation, be careful not to peel off the sealant applied on the timing cover from contact with other parts.

Install the new O-ring (A).

Courtesy of KIA MOTORS AMERICA, INC.

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

A (21 pcs):

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

B (2 pcs):

24.5 - 26.5 N.m (2.5 - 2.7 kgf.m, 18.1 - 19.5 lb.ft)

C (2 pcs):

58.8 - 68.8 N.m (6.0 - 7.0 kgf.m, 43.4 - 50.6 lb.ft)

D (3 pcs):

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

Courtesy of KIA MOTORS AMERICA, INC.

Do not run the engine or perform pressure test within 30 minutes of assembly.

Install the engine mounting support bracket.

Install the engine mounting support bracket (A).

Tightening torque:

88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Once the self lock nut is loosened, it lose the clamping force. For the reason, always use a new nut to tighten with specified torque.

Connect the ground cable (A).

Courtesy of KIA MOTORS AMERICA, INC.

Remove the jack from the upper oil pan.

Install the RH and LH 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)

[RH]

Courtesy of KIA MOTORS AMERICA, INC.

[LH]

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.

After replacing the O-ring (A) of variable force solenoid (VFS) valve, apply engine oil on new O-ring (A).

Courtesy of KIA MOTORS AMERICA, INC.

Push variable force solenoid (VFS) valve up to the timing chain cover, and temporarily tighten the bolt.
Tighten the variable force solenoid (VFS) valve to the specified torque.

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.