Repair procedures: Installation

Dowel pin of crankshaft should be positioned at 3° in relation to vertical center line.

Fig 1: Identifying Crankshaft Dowel Pin 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: Aligning CVVT Sprockets TDC Marks With Cylinder Head Upper Surface
Courtesy of KIA MOTORS AMERICA, INC.
Install the new O-rings (A).

Fig 3: Identifying 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: Identifying Timing Chain And Guide
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: Identifying 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: Identifying 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 ~ 5mm (0.1181~0.1969in.)
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: Identifying Liquid Gasket Applying Areas On Water Pump Contact Parts And Rest Parts
  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: Identifying 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:

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

Fig 10: Identifying Crankshaft Pulley
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 11: 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 12: Identifying Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 13: Identifying Dust Cover And Transaxle Mounting Bolts
  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 70mm(2.7559in) in the original mounted hole.
  
  Fig 14: Identifying Holder, Holder Nuts, Ring Gear And Links
  Courtesy of KIA MOTORS AMERICA, INC.
5. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 15: Tightening Holder And Link Mounting Bolts And Nuts Using Tool (09231-3D100)
  Courtesy of KIA MOTORS AMERICA, INC.
NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 16: Identifying Pulley Grooves Positions
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 17: Identifying Water Pump
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque:

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

B: 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Fig 18: Identifying Water Pump Pulley And Drive Belt Idler
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 19: Identifying Engine Support Bracket And Alternator 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):

78.4 ~ 98.0N.m (8.0 ~ 10.0kgf.m, 57.8 ~ 72.3lb-ft)

Bolt (D) and nuts (E):

58.8 ~ 73.5N.m (6.0 ~ 7.5kgf.m, 43.4 ~ 54.2lb-ft)

Fig 20: Identifying Engine Mounting Support Bracket, Ground Line, Mounting Bolts And Nuts
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 21: Identifying Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).

Fig 22: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Adjust tension by tightening the alternator tension adjust bolt (A). (Refer to REMOVAL AND INSTALLATION .
Tension

[With OAD]

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

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

[Without OAD]

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

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

Fig 23: Identifying Alternator Tension Adjust Bolt
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 ~ 2.5mm(0.0787~0.0984in.)

Fig 24: Identifying Liquid Gasket Applying Areas On Cylinder Head Cover
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 25: Identifying Oil Control Valve 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 26: Identifying 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 27: Tightening Order Of Cylinder Head Cover Bolts
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 28: Identifying 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 29: Identifying Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to FUEL DELIVERY SYSTEM )
Tightening torque:

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

Fig 30: Identifying 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 31: Identifying 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 ~ 31.4N.m (2.6 ~ 3.2kgf.m, 18.8 ~ 23.1lb-ft)

Fig 32: Identifying 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 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Fig 33: Identifying Vacuum Pipe Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Connect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 34: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the oxygen sensor connectors (A) and the condenser connector (B).

Fig 35: Identifying 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 36: Identifying Fuel Pressure Control Valve Connector, Intake And Exhaust Camshaft Position Sensor 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 37: Identifying 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 38: Identifying 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 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.8lb-ft)

Fig 39: Identifying A/C Compressor Switch Connector, Alternator Connector And Alternator B 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 40: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.

Fig 41: Identifying Under Cover
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.
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Connect the breather hose (C).
3. Install the air duct (B).
4. Connect the battery negative terminal (A).
  Tightening torque:
  
  Without battery sensor:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  With battery sensor:
  
  4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
  
  Fig 42: Identifying Battery Negative Terminal, Air Duct, Breather Hose And Air Cleaner Assembly
  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: Identifying Air Intake Hose Installation Position
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover.
Make sure the engine cover is installed before driving.