Repair procedures: Installation

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
Always use a new cylinder head bolt.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.

Install the cylinder head gasket (A) on the cylinder block.
NOTE: Be careful of the installation direction.

Fig 1: Identifying Cylinder Head Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
Install the cylinder head bolts.
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
  Tightening torque :
  
  29.4N.m (3.0kgf.m, 21.7lb-ft) + 90° → Release all bolts → 29.4N.m (3.0kgf.m, 21.7lb-ft) + 90°
  
  Fig 2: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting support bracket fixing bolts (A).

Fig 3: Identifying Engine Mounting Support Bracket Fixing Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the OCV (Oil Control Valve) filter (A).
Tightening torque :

40.2 ~ 50.0N.m (4.1 ~ 5.1kgf.m, 29.7 ~ 36.9lb-ft)

Fig 4: Identifying OCV (Oil Control Valve) Filter
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Always use a new OCV (Oil Control Valve) filter gasket.
- Keep clean the OCV (Oil Control Valve) filter.
Install the OCV (Oil Control Valve) (A).
Tightening torque :

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

Fig 5: Identifying OCV (Oil Control Valve)
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Do not reuse the OCV (Oil Control Valve) when dropped.
- Keep clean the OCV (Oil Control Valve).
- Do not hold the OCV (Oil Control Valve) sleeve during servicing.
- When the OCV (Oil Control Valve) is installed on the engine, do not move the engine with holding the OCV (Oil Control Valve) yoke.
Install the camshafts.
1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
  
  Fig 6: Identifying Intake Timing Chain Sprocket And Exhaust Timing Chain Sprocket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the camshaft (A) and bearing caps (B).
  Tightening torque :
  
  11.8 ~ 13.7N.m (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lb-ft)
  
  Fig 7: Identifying Camshaft And Bearing Caps
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the timing chain auto tensioner (A).
  Tightening torque :
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 8: Identifying Timing Chain Auto Tensioner
  Courtesy of KIA MOTORS AMERICA, INC.
Using the SST (09221 - 21000), install the camshaft bearing oil seal.

Fig 9: Installing Camshaft Bearing Oil Seal Using SST (09221 - 21000)
Courtesy of KIA MOTORS AMERICA, INC.
Install the camshaft sprocket. (Refer to CAMSHAFT )
Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).
  
  Fig 10: Identifying Cylinder Head Cover Gasket And Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove.
  - When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap.
2. Apply liquid gasket to the head cover gasket at the corners of the recess.
  
  Fig 11: Identifying Liquid Gasket Applying Area On Head Cover Gasket
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Use liquid gasket, Loctite No. 5999.
  - Check that the mating surfaces are clean and dry before applying liquid gasket.
  - After assembly, wait at least 30 minutes before filling the engine with oil.
3. Install the cylinder head cover (A) with bolts (B).
  Uniformly tighten the bolts in several passes.
  
  Pre-tighten all bolts by 3.9~4.9N.m (0.4~0.5kgf.m, 2.9~3.6lb-ft) and then tighten by the specified torque.
  
  Tightening torque :
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 12: Identifying Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
Install the timing belt. (Refer to TIMING BELT )
Install the intake manifold. (Refer to INTAKE MANIFOLD )
Install the exhaust manifold. (Refer to EXHAUST MANIFOLD )
Install the ignition coil. (Refer to IGNITION SYSTEM ).
Install the power steering pump. (Refer to HYDRAULIC POWER STEERING SYSTEM )
Install the brake booster hose (B).
Connect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.

Fig 13: Identifying PCSV (Purge Control Solenoid Valve) Hose And Brake Booster Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
1. Install the wire harness bracket (E).
2. Connect the ground cable (D).
3. Connect the CMP (Camshaft position sensor) connector (C).
4. Connect the ignition coil condenser connector (B).
5. Connect the ignition coil connector (A).
  
  Fig 14: Identifying Ignition Coil Connector, Ignition Coil Condenser Connector And CMP (Camshaft Position Sensor) Connector
  Courtesy of KIA MOTORS AMERICA, INC.
6. Connect the OCV (Oil Control Valve) connector (C).
7. Connect the CKP (Crankshaft Position Sensor) connector (B).
8. Connect the front oxygen sensor connector (A).
  
  Fig 15: Identifying Front Oxygen Sensor Connector And CKP (Crankshaft Position Sensor) Connector
  Courtesy of KIA MOTORS AMERICA, INC.
9. Connect the ISA (Idle Speed Actuator) connector (B).
10. Install the wire harness bracket (A).
  
  Fig 16: Identifying Wire Harness Bracket And ISA (Idle Speed Actuator) Connector
  Courtesy of KIA MOTORS AMERICA, INC.
11. Connect the injector connectors (No. 1, 2) (E).
12. Connect the injector connectors (No. 3, 4) (D).
13. Connect the knock sensor connector (C).
14. Connect the air conditioner compressor switch connector (B).
15. Connect the rear oxygen sensor connector (A).
  
  Fig 17: Identifying Rear Oxygen Sensor Connector, Air Conditioner Compressor Switch Connector And Knock Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Connect the TPS (Throttle Position Sensor) connector (B).
Install the accelerator cable (A).

Fig 18: Identifying Accelerator Cable And TPS (Throttle Position Sensor) Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the fuel hose (B).
Install the heater hoses (A).

Fig 19: Identifying Heater Hoses And Fuel Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the upper radiator hose (A) and lower radiator hose (B).

Fig 20: Identifying Upper Radiator Hose And Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the battery tray (A).

Fig 21: Identifying Battery Tray
Courtesy of KIA MOTORS AMERICA, INC.
Install the intake air hose and air cleaner assembly.
1. Install the air cleaner element and air cleaner lower cover (C).
  Tightening torque :
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Connect the ECM connector (A) and ECM connector (B) (A/T only).
  
  Fig 22: Identifying ECM Connector And ECM Connector
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the intake air hose (D) and air cleaner upper cover (C).
4. Connect the breather hose (B) to intake air hose (D).
5. Connect the AFS (Air Flow Sensor) connector (A).
  
  Fig 23: Identifying AFS (Air Flow Sensor) Connector, Breather Hose And Intake Air Hose
  Courtesy of KIA MOTORS AMERICA, INC.
Install the under cover (A).

Fig 24: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover (A).
Tightening torque :

3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Fig 25: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the battery and connect the battery terminals (A).

Fig 26: Identifying Battery Terminals
Courtesy of KIA MOTORS AMERICA, INC.
Fill with engine coolant. (Refer to ENGINE COOLANT REFILLING AND BLEEDING )
Start the engine and check for leaks.
Recheck engine coolant level and oil level.