Timing Belt: Installation

Install crankshaft sprocket "B" into crankshaft.
CAUTION: Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.

Fig 1: Installing Crankshaft Sprocket "B"
Courtesy of KIA MOTORS AMERICA, INC.
Lightly apply engine oil to the outer surface of spacer, and then install the spacer to the right counter balance shaft. Be sure to install in the direction as shown in illustration.

Fig 2: Installing Spacer To Right Counter Balance Shaft
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Install the counter balance shaft sprocket onto the right counter balance shaft, and then tighten flange bolt finger tight.
Align the timing mark on each sprocket with the corresponding timing mark on the front case.

Fig 3: Locating Timing Marks Of Timing Belt
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When the timing belt "B" is installed, make certain that tension side has no slack. Install tensioner "B" with center of pulley located on the left side of mounting bolt.

Fig 4: Checking & Adjusting Tension Of Timing Belt (1 Of 2)
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Lift tensioner "B" to tighten the timing belt "B" so that its tension side will be pulled tight. In this condition, tighten a bolt to secure tensioner "B". When a bolt is tightened, be careful to prevent from turning shaft. If the shaft is turned together, the belt will be overtightened.

Fig 5: Checking & Adjusting Tension Of Timing Belt (2 Of 2)
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Check to ensure that timing marks are in alignment.
Check to ensure that when the center of span on the tension side is depressed with index finger in direction of arrow, deflection of belt is within specification.
Belt deflection: 5-7 mm (0.2-0.3 in.)

Fig 6: Checking Timing Belt Tension "B" Deflection
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Install sensing blade and crankshaft sprocket onto crankshaft. Be sure to install in the direction as shown in illustration.
CAUTION: Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could result.

Fig 7: Installing Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the special washer and sprocket bolt to crankshaft, and then tighten the sprocket bolt.
Tightening torque

Crankshaft sprocket bolt :

110-130 Nm (1100-1300 kg.cm, 80-94 lb.ft)
Insert a screwdriver through the plug hole in left side of cylinder block to keep shaft in position.

Fig 8: Installing Screwdriver In Plug Hole To Hold Shaft In Position
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Install the oil pump sprocket, and tighten the nut to the specified torque.

Fig 9: Installing Oil Pump Sprocket
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Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque

Camshaft sprocket bolt :

80-100 Nm (800-1000 kg.cm, 56-72 lb.ft)

Fig 10: Installing Camshaft Sprocket (1 Of 2)
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Fig 11: Installing Camshaft Sprocket (2 Of 2)
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Install the auto tensioner.
CAUTION: Leave the set pin installed in the auto tensioner

Tightening torque

Auto tensioner bolt :

19.6-26.5 Nm (2.0-2.7 kg.cm, 145-19.5 lb.ft)

Fig 12: Installing Auto Tensioner
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NOTE:
If the auto tensioner rod is in its fully extended position, reset it as follows.
- Clamp it in the vise with soft jaws in a level position. Apply a plain washer if there is a plug at the bottom of the auto tensioner.
- Push in the rod slowly with the vise until the set hole A in the rod is aligned with the set hole B in the cylinder.
- Insert a wire to the set hole A and B.
Fig 13: Resetting Auto Tensioner For Installation
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Install the tensioner pulley onto the tensioner arm.
CAUTION: Leave the wire installed in the auto tensioner.

Fig 14: Installing Tensioner Pulley
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Align the timing marks of the camshaft sprocket to the timing marks of the rocker cover. The dowel pin of the camshaft sprocket should be at the upper side.

Fig 15: Identifying Camshaft Timing Marks (1 Of 2)
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NOTE:
- The identification mark is on the camshaft sprocket.
- Before installing timing belt, if the timing marks of camshaft sprocket and rocker cover do not coincide, do not rotate the camshaft sprocket more than 2 teeth of sprocket in any direction. Rotating sprocket more than 2 teeth allows valve and piston to touch each other.
- In case of rotating the camshaft sprocket in avoidably more than 2 teeth, rotate the camshaft sprocket after rotating crankshaft sprocket counter clockwise on basis of timing mark.
Fig 16: Identifying Camshaft Timing Marks (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Align the timing marks of each sprocket and install the timing belt in this order. Crankshaft sprocket-Oil pump sprocket-Idler pulley-Exhaust camshaft sprocket-Intake camshaft sprocket-Tensioner pulley.
NOTE:
- In this step, No. 1 is in TDC (Compression stroke).
- When the timing mark of oil pump sprocket is aligned, first remove the plug at left side of the cylinder block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 in) in diameter which can be inserted more than 60 mm (2.36 in).
- Install the plug at left side of the cylinder block after check timing.
Fig 17: Aligning Timing Marks
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Fig 18: Holding Counter Balance Shaft With Screwdriver
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Remove the wire from the auto tensioner.
Rotate the crankshaft two complete turns clockwise and leave it as is for about 5 minutes. Then, measure the auto tensioner protrusion "A" (distance between the tensioner arm and auto tensioner body) to ensure that it is up to specification. If the protrusion exceeds specification, repeat step 14-18
Standard value : 5.5-9.0 mm (0.22-0.35 in.)

Fig 19: Checking Auto Tensioner Protrusion
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Install the timing belt lower cover and the timing belt upper cover.

Fig 20: Installing Timing Belt Upper & Lower Cover

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