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Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the camshaft sprocket and tighten the bolt to the specified torque.
    1. Temporarily install the camshaft sprocket bolt.
    2. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the camshaft sprocket (C) bolt.

      Tightening torque 

      Camshaft sprocket bolt:

      98.1 ~ 117.7 Nm (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8 lb-ft)

      Fig 1: Installing Camshaft Sprocket
      G06523297Courtesy of KIA MOTORS AMERICA, INC.
  2. Install cylinder head cover.
    1. Install cylinder head cover (A) with the twelve bolts (B).
      Fig 2: Identifying Cylinder Head Cover & Bolts
      G06523298Courtesy of KIA MOTORS AMERICA, INC.

      Tightening torque: 

      7.8 ~ 9.8 Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

    2. Install the PCV hose (A) and breather hose (B).
    3. Install the accelerator cable (C) and the auto-cruise cable (D) from the cylinder head cover.
      Fig 3: Identifying PCV Hose, Breather Hose, Accelerator Cable, & Auto-Cruise Cable
      G06523299Courtesy of KIA MOTORS AMERICA, INC.
    4. Install the spark plug cable.
    Fig 4: Identifying Spark Plug Cables
    G06523300Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the crankshaft sprocket (A).
    Fig 5: Identifying Crankshaft Sprocket
    G06523301Courtesy of KIA MOTORS AMERICA, INC.
  4. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at top dead center and its compression stroke.
    Fig 6: Identifying Timing Marks Of Camshaft Sprocket
    G00563574Courtesy of KIA MOTORS AMERICA, INC.
    Fig 7: Identifying Timing Marks Of Crankshaft Sprocket
    G00563575Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the idler pulley (A) and tighten the bolt (B) to the specified torque.

    Tightening torque 

    Idler pulley bolt:

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

    Fig 8: Identifying Idler Pulley & Bolt
    G06523304Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the timing belt tensioner loosely enough for the adjuster to rotate. Make sure that the stopper of base is leaning against the lowering sealing cap on the cylinder head.
  7. Tighten belt enough so that it doesn't give slack at each center of the shaft. Do as following procedures when installing timing belt.

    Crankshaft sprocket (A) → Idler pulley (B) → Camshaft sprocket (C) → timing belt tensioner (D).

    (The tensioner can be installed after the timing belt.)

    Fig 9: Identifying Crankshaft Sprocket, Idler Pulley, Camshaft Sprocket, & Timing Belt Tensioner
    G06523305Courtesy of KIA MOTORS AMERICA, INC.
  8. Check the alignment of the timing marks on each sprocket.
  9. Remove the pin fixing the tensioner arm.
  10. Using a hex wrench, turn the adjuster counterclockwise to make the indicator of the arm (A) located at the center of the base notch.
    Fig 10: Turning Adjuster Counterclockwise
    G06523306Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Do not rotate the adjuster clockwise.
    It will result in functional problem with auto tensioner.
  11. Tightening tensioner bolt with fixing the indicator not to move.

    Tightening torque 

    Tensioner bolt:

    22.6 ~ 28.4 Nm (2.3 ~ 2.9kgf.m, 16.6 ~ 21.0 lb-ft)

  12. Turn the crankshaft two revolutions in the operating direction (clockwise) and check that the indicator is in the center of base.
  13. If the indicator is not located at the center of base, slacken the bolt and repeat the above procedure.
  14. Install the timing belt lower cover (A) with 5 bolts (B).

    Tightening torque 

    Timing belt cover bolt:

    7.8 ~ 9.8 Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

    Fig 11: Identifying Timing Belt Lower Cover & Bolts
    G06523307Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the flange and crankshaft pulley (A).

    Make sure that crankshaft sprocket pin fits the small hole in the pulley.

    Tightening torque 

    Crankshaft pulley bolt:

    156.9 ~ 166.7 N.m (16.0 ~ 17.0kgf.m, 115.7 ~ 123.0 lb-ft)

    Fig 12: Identifying Crankshaft Pulley & Bolt
    G06523308Courtesy of KIA MOTORS AMERICA, INC.
  16. Install the timing belt upper cover (A).

    Tightening torque: 

    7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

    Fig 13: Identifying Timing Belt Upper Cover
    G06523309Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the coolant pump pulley with 4 bolts.

    Tightening torque: 

    7.8 ~ 9.8 Nm (0.8 ~ 1.0kgf.m 5.8 ~ 7.2 lb-ft)

    Fig 14: Installing Coolant Pump Pulley Bolts
    G06523310Courtesy of KIA MOTORS AMERICA, INC.
  18. Install power steering belt.
  19. Install air compressor belt.
  20. Install alternator belt.
  21. Install the engine mount bracket
    1. Install the stay plate (A) with bolt (B).

      Tightening torque 

      Stay plate bolt:

      42.2 ~ 53.9 Nm (4.3 ~ 5.5kgf.m 31.1 ~ 39.8 lb-ft)

      Fig 15: Identifying Stay Plate & Bolt
      G06523311Courtesy of KIA MOTORS AMERICA, INC.
    2. Install engine mount bracket (A).

      Tightening torque 

      Nut (B):

      78.5 ~ 98.1 N.m (6.5 ~ 8.5kgf.m, 57.9 ~ 72.3 lb-ft)

      Bolt (C), Nuts (D):

      58.8 ~ 73.5 N.m (5.0 ~ 6.5kgf.m, 43.4 ~ 54.2 lb-ft)

      Fig 16: Identifying Engine Mount Bracket, Nuts, & Bolt
      G06523312Courtesy of KIA MOTORS AMERICA, INC.
  22. Install RH side cover (A).
    Fig 17: Identifying RH Side Cover
    G06523313Courtesy of KIA MOTORS AMERICA, INC.
  23. Install RH front wheel.
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