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Home >> Kia >> 2021 >> K5 GT-Line, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 12 (Timing System - 2.5L) >> Timing Chain Cover >> Repair Procedures >> Installation
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Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the timing chain cover.
    1. Make sure to remove the hardening sealant, foreign materials, oil, dust and moisture gathered in the liquid gasket sealing surface (cam carrier, cylinder head, cylinder block, lower crankcase). Then, spray the cleaner on the sealing surface and wipe off with a clean towel.
    2. Apply a sealant for liquid gasket to the interface between the cam carrier, cylinder head, cylinder block and lower crankcase.

      Bead width:  3.0 - 5.0 mm (0.11 - 0.19 in.)

      Sealant:  FIPG TYPE AAO (MS721-40)

      G13837184Courtesy of KIA MOTORS AMERICA, INC.
    3. The part must be assembled within 5 minutes after sealant was applied on the mounting surface of liquid gasket of timing chain cover.

      Bead width:  2.5 - 3.5 mm (0.11 - 0.19 in.)

      Sealant:  FIPG TYPE AAO (MS721-40)

      G13837185Courtesy of KIA MOTORS AMERICA, INC.
    4. 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: 

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

      Bolts (B): 18.6 - 22.5 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

      G13837186Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.
      • Always install the timing chain cover mounting bolt (D) with a new one.
  2. Replace the front oil seal if neccesary.

    (Refer to " Replacement  ") 

  3. Remove it by breaking the center of E-CVVT motor plug (A).
    G13837187Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Remove after 30 minutes of switching "OFF" the ignition to drain out the oil inside the E-CVVT motor plug.
    • Do not tilt the front of engine (timing chain cover side) downward as residual oil may flow out during E-CVVT motor plug removal.
    • If oil flows out during E-CVVT motor plug removal, wipe off immediately and block the motor shaft inlet with a clean towel.
  4. Clean the E-CVVT motor plug mounting surface (A) with oil cleaner.
    G13837188Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • If the surface is not cleaned, E-CVVT motor plug may be separated due to diminished separation force from residual oil.
    • When spraying oil cleaner, block around the motor shaft inlet and rotor gap with a clean towel to prevent inflow of oil from flowing into the rotor gap.
  5. When reusing the E-CVVT cover, inspect the below items.
    1. If there is sign of leakage from inside the E-CVVT cover, replace it with a new one.
    2. Check the connector brush wear condition.

      Specification:  More than 5 mm (0.1969 in.)

      G13837189Courtesy of KIA MOTORS AMERICA, INC.

      If measurement is below specification, replace the E-CVVT cover with a new one.

    3. Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.
      G13837190Courtesy of KIA MOTORS AMERICA, INC.
    4. After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.
      G13837191Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the E-CVVT cover.
    1. Apply engine oil to the oil seal lip (A).
      G13837192Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: When applying oil, keep the connector brush (A) clean from foreign materials.
      G13837193Courtesy of KIA MOTORS AMERICA, INC.
    2. Insert SST(09243 - C2000) into the E-CVVT motor shaft.
      G13837194Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Correctly mount SST on to the motor shaft.
    3. Slowly push the E-CVVT cover (A) until it is flushed with the timing chain cover surface.
      G13837195Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Installing the E-CVVT cover without SST may cause oil leakage inside the E-CVVT motor due to damaged or separated E-CVVT oil seal.
    4. Pre-tighten the bolts in the below sequence, and then remove the SST(09243 - C2000).

      Tightening torque: 

      0.9 - 1.9 N.m (0.1 - 0.2 kgf.m, 0.7 - 1.4 lb.ft, 8.7 - 17.4 lb.in)

      Fig 1: E-CVVT Cover Bolts Tightening Sequence
      G13837196Courtesy of KIA MOTORS AMERICA, INC.
    5. Tighten the bolts to the specified torque in the sequence below.

      Tightening torque: 

      9.8 - 11.7 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.6 lb.ft)

      Fig 2: E-CVVT Cover Bolts Tightening Sequence
      G13837197Courtesy of KIA MOTORS AMERICA, INC.
  7. Install the E-CVVT plug.
    1. By using SST(09243 - C2000), insert the plug into the E-CVVT cover hole.
      G13837198Courtesy of KIA MOTORS AMERICA, INC.
    2. Mount the stopper of SST(09243 - C2000) so that it sits at the end of E-CVVT motor shaft.
      G13837199Courtesy of KIA MOTORS AMERICA, INC.
  8. Inspect the pressed depth of E-CVVT plug.
    1. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of motor shaft (1).
    2. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT plug (2).
      G13837200Courtesy of KIA MOTORS AMERICA, INC.
    3. Calculate the pressed depth (3) of motor plug.

      If out of specification, reinstall after replacing the E-CVVT plug with a new one.

      Pressed depth:1 = 2 - 3

      Specification - 2.1 mm (0.0433 - 0.0826 in.)

  9. Insert the E-CVVT cover plug so that the protrusion reach to E-CVVT cover groove correctly.
    G13837201Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Check how much protrude after installing the E-CVVT cover plug.
      G13837202Courtesy of KIA MOTORS AMERICA, INC.
    • Be careful that the plug is not inserted inside E-CVVT cover beyond the regulated range.
    NOTE: When replacing or reinstalling the electric E-CVVT assembly, make sure to reset the value of learning using additional function menu of KDS diagnostic.
    (Refer to  Installation 
  10. Install the variable force solenoid valves (VFS) (A).

    Tightening torque: 

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

    G13837203Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Do not reuse the variable force solenoid valve (VFS) if it is dropped.
    • When installing the variable force Solenoid valve (VFS), pay attention to the following points.
      1. After replacing the variable force Solenoid valve (VSF) O-ring (A) with a new one, apply engine oil to the new O-ring (A).
      2. Push the variable force solenoid valve (VFS) to the end of the timing chain cover mounting surface, and then pre-tighten the bolts.
      3. Tighten the variable force solenoid valve (VFS) with specified torque.
  11. Install in the reverse order of removal.
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