Timing Chain: Reassembly

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

Fig 1: Identifying Key Of Crankshaft And Timing Mark Of Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install tensioner adapter assembly (A).

Fig 2: Identifying Tensioner Adapter Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install crankshaft sprocket (A) (LH camshaft drive).

Fig 3: Identifying Crankshaft Sprocket (LH Camshaft Drive)
Courtesy of KIA MOTORS AMERICA, INC.
Install LH timing chain guide (A).
Tightening torque

19.60 ~ 24.50 Nm (2.0 ~ 2.5 kgf.m, 14.17 ~ 18.08 lb-ft)

Fig 4: Identifying LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.

Crankshaft sprocket (A) → Timing chain guide (B) → Exhaust camshaft sprocket (C) → Intake camshaft sprocket (D).

The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 5: Identifying LH Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.
Install LH timing chain tensioner arm (B).
Tightening torque

18.62 ~ 21.56 Nm (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
Install chain tensioner (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 6: Identifying Chain Tensioner And LH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install LH cam-to-cam guide (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 7: Identifying LH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install crankshaft sprocket (A) (O/P & RH camshaft drive).

Fig 8: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install oil pump chain (B) and oil pump sprocket (A).
Tightening torque

18.62 ~ 21.56 Nm (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)

Fig 9: Identifying Oil Pump Sprocket And Oil Pump Chain
Courtesy of KIA MOTORS AMERICA, INC.
Install RH timing chain guide (A).
Tightening torque

19.60 ~ 24.50 Nm (2.0 ~ 2.5 kgf.m, 14.17 ~ 18.08 lb-ft)

Fig 10: Identifying RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.

Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C).

The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 11: Identifying Timing Mark Of Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.

Fig 12: Identifying Timing Mark Of Sprockets And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.
Install RH timing chain tensioner arm (B).
Install RH timing chain auto tensioner (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 13: Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install RH cam-to-cam guide (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 14: Identifying RH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install oil pump chain guide (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 15: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install oil pump chain tensioner assembly (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 16: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Pull out the pins of hydraulic tensioner (LH & RH).
Install oil pump chain cover (A).
Tightening torque

9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 17: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
Install timing chain cover.
1. 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.
2. Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block
  The part must be assembled within 5 minutes after sealant was applied.
  
  Bead width: 2.5 mm (0.1 in.)
  
  Fig 18: Identifying Sealant Locations On Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. After applying liquid sealant TB1217H on timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Sealant should be applied without discontinuity.
  
  Sealant should also be applied all around the two holes of the dowel pins.
  
  Bead width: 2.5 mm (0.1 in.)
  
  Fig 19: Identifying Sealant Bead Width
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 20: Identifying Timing Chain Cover Gasket
  Courtesy of KIA MOTORS AMERICA, INC.
5. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
  Tightening torque
  
  B (17): 18.62 ~ 21.56 Nm (1.9 ~ 2.2 kgf.m, 13.74 ~ 15.91 lb-ft)
  
  C (4): 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  D (1): 58.80 ~ 68.80 Nm (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  
  E (1): 58.80 ~ 68.80 Nm (6.0 ~ 7.0 kgf.m, 43.40 ~ 50.63 lb-ft)
  
  F (2): 24.50 ~ 26.46 Nm (2.5 ~ 2.7 kgf.m, 18.08 ~ 19.53 lb-ft)
  
  G (4): 21.56 ~ 23.52 Nm (2.2 ~ 2.4 kgf.m, 15.91 ~ 17.36 lb-ft)
  
  H (1): 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  I (1): 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  J (1): 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  K (4): 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  L (1): 21.56 ~ 26.46 Nm (2.2 ~ 2.7 kgf.m, 15.91 ~ 19.53 lb-ft) - New bolt
  
  Fig 21: Identifying Cylinder Block Dowel Pins And Holes On Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
6. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 22: Installing Timing Chain Cover Oil Seal Using SST (09231-3C100)
Courtesy of KIA MOTORS AMERICA, INC.
Install lower oil pan.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
  The part must be assembled within 5 minutes after the sealant was applied.
  
  Bead width: 2.5 mm (0.1 in.).
  
  Fig 23: Identifying Sealant Applying Area On Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Make clean the sealing face before assembling two parts.
  - Remove harmful foreign matters on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  - To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install oil pan (A).
  Uniformly tighten the bolts in several passes.
  
  Tightening torque
  
  9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 24: Identifying Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
Using SST (09231-3C300) install crankshaft damper pulley (A).
Tightening torque

284.2 ~ 303.8 Nm (29.0 ~ 31.0 kgf.m, 209.76 ~ 224.22 lb-ft)

Fig 25: Identifying Crankshaft Damper Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 26: Identifying SST (09231-3C300) On Crankshaft Damper Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width: 2.5 mm (0.1 in.)
  
  Fig 27: Identifying Sealant Applying Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
4. Install the cylinder head cover bolts as following method.
  Tightening torque
  
  9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
  
  Fig 28: Identifying Cylinder Head Cover Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: Do not reuse cylinder head cover gasket.
5. Install ignition coil
6. Connect RH ignition coil connector (A), condenser connector (B) and install wiring bracket (C).
  
  Fig 29: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
7. Install connector bracket from LH cylinder head cover.