Timing Chain: Installation

WARNING: This page is about a different car, the 2013 Kia Sportage and 2012 Kia Sportage. However, it is still accessible from the selected car via links, so may be relevant.

Install the balance shaft chain. (Refer to LUBRICATION SYSTEM in this group)
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening torque:

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

Fig 1: Identifying Crankshaft Chain Sprocket And Timing Chain Oil Jet
Courtesy of KIA MOTORS AMERICA, INC.
Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 2: Identifying Crankshaft Key
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: Identifying Intake And Exhaust Camshaft Assembly TDC Marks
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening torque:

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

Fig 4: Identifying Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D).

Fig 5: Identifying Timing Chain Installing Sequence
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.

Fig 6: Identifying Chain Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Identifying Sprockets Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening torque:

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

Fig 8: Identifying Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain auto tensioner (B) and remove the stopper pin (A).
Tightening torque:

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

Fig 9: Identifying Timing Chain Auto Tensioner And Stopper Pin
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks (A) on the intake and exhaust CVVT sprockets aligned with the top surface of cylinder head.

Fig 10: Identifying CVVT Sprockets Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain cover.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and etc.
3. Before assembling the timing chain cover, liquid sealant Loctite 5900H or equivalent should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.
  Bead width: 3.0mm (0.12in.)
  
  Fig 11: Identifying Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
4. After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.
  
  Bead width: 3.0mm (0.12in.)
  
  Fig 12: Identifying Liquid Sealant Applying Area
  Courtesy of KIA MOTORS AMERICA, INC.
5. 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 (M6x25):

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

Bolts B (M8x28):

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

Fig 13: Identifying Dowel Pins Location
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.
Install the engine support bracket (A).
Tightening torque:

M10 bolts:

39.2 ~ 44.1N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 32.5lb-ft)

M8 bolts:

19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

Fig 14: Identifying Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft front oil seal (A) using SST (09214-3K000, 09231-H1100) (B).

Fig 15: Installing Crankshaft Front Oil Seal Using SST (09214-3K000, 09231-H1100)
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (A).
Tightening torque:

53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Fig 16: Identifying Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).
Tightening torque:

Idler (A):

53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Water pump pulley (B):

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

Crankshaft pulley (C):

166.6 ~ 176.4N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1lb-ft)

Drive belt tensioner pulley (D):

53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Fig 17: Identifying Idler, Water Pump Pulley, Crankshaft Pulley And Drive Belt Tensioner Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left-handed screw.

NOTE: Use the SST (Ring gear stopper, 09231-2B100) to remove the crankshaft pulley bolt. Install the starter after installing the crankshaft pulley.

Fig 18: Removing Crankshaft Pulley Bolt Using SST (Ring Gear Stopper, 09231-2B100)
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting support bracket (B) and connect the ground line (A).
Tightening torque:

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Fig 19: Identifying Engine Mounting Support Bracket And Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Remove the jack from the ladder frame.
Install the oil pan.
1. Using a gasket scraper, remove all the old sealant material from the gasket surfaces.
2. Before assembling the oil pan, liquid sealant Loctite 5900H, Threebond 1217H or equivalent should be applied on oil pan. The part must be assembled within 5 minutes after sealant was applied.
  Bead width : 2.5mm (0.10in.)
  
  Fig 20: Identifying Oil Pan Sealant Applying Area
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  - To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
3. Install the oil pan (A). Uniformly tighten the bolts in several passes.
  Tightening torque
  
  Bolts B (M9):
  
  30.4 ~ 34.3N.m (3.1 ~ 3.5kgf.m, 22.4 ~ 25.3lb-ft)
  
  Bolts C (M6):
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Fig 21: Identifying Oil Pan And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.

NOTE: Always use a new drain plug gasket.
Install the A/C compressor bracket (A).
Tightening torque:

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

Fig 22: Identifying A/C Compressor Bracket And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the A/C compressor lower bolts (A).
Tightening torque:

20.0 ~ 33.0N.m (2.04 ~ 3.36kgf.m, 14.8 ~ 24.3lb-ft)

Fig 23: Identifying A/C Compressor Lower Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate the drive belt tensioner arm (B) counterclockwise moving the tensioner pulley bolt with wrench. After putting the belt on the tensioner pulley, release the tensioner pulley slowly.

Fig 24: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant, it should be assembled within 5 minutes.
  Bead width : 2.5mm (0.10in.)
  
  Fig 25: Identifying Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover (A) by tightening the bolts as following method.
Tightening torque

1st step: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

2nd step: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig 26: Identifying Cylinder Head Cover And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.

Fig 27: Identifying Cylinder Head Cover Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Do not reuse cylinder head cover gasket.
- The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
Install the front engine hanger (B) and then connect the PCV (Positive crankcase ventilation) hose (A).
Tightening torque:

27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

Fig 28: Identifying Front Engine Hanger And Positive Crankcase Ventilation Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to Fig 29.
Tightening torque:

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

Fig 29: 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.

NOTE: 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 30: Identifying O-Ring Of High Pressure Fuel Pump, Roller Tappet And Protrusion
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure pipe (A). (Refer to Fig 31.
Tightening torque:

Bolt: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

Nuts: 26.5 ~ 32.4N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9lb-ft)

Fig 31: Identifying High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not reuse the high pressure pipe.
Connect PCSV (Purge control solenoid valve) connector (A) and tighten the vacuum pipe assembly mounting bolts and nut.

Fig 32: Identifying Purge Control Solenoid Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

Fig 33: Identifying Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the ignition coils (A).
Tightening torque:

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

Fig 34: Identifying Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connectors (B) and fuel pump connector (A) after installing the wiring protector.

Fig 35: Identifying Ignition Coil Connectors And Fuel Pump Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B).

Fig 36: Identifying Exhaust Oil Control Valve Connector And Oxygen Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the under cover (A).
Tightening torque:

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

Fig 37: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the intercooler inlet pipe & hose assembly (C) and then connect the recirculation valve connector (A) and the vacuum hose (B).
Tightening torque

Hose clamp bolt:

4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

Pipe mounting bolt:

14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

Fig 38: Identifying Recirculation Valve Connector, Vacuum Hose And Intercooler Inlet Pipe Hose Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (F) and then connect the air intake hose (E).
  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 (B), the recirculation hose (C) and the brake booster vacuum hose (D).
3. Install the air duct (A).
Fig 39: Identifying Air Duct, Breather Hose, Recirculation Hose And Brake Booster Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

Fig 40: Identifying Battery Negative Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover.
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.

NOTE:

Refill engine with engine oil.
Refill a transaxle with fluid.
Refill a radiator and a reservoir tank with engine coolant.
Clean battery posts and cable terminals and assemble.
Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Refill radiator and reservoir tank with engine coolant.
Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks