Repair Procedures: Installation

Install the balance shaft chain.
(Refer to "BALANCE SHAFT & OIL PUMP ")
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening torque :

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

Fig 1: Installing Crankshaft Chain Sprocket & 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: Locating Key Of Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: Aligning TDC Marks Of Intake & Exhaust CVVT Sprockets
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 4: Locating Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening torque :

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

Fig 5: Installing Timing Chain Guide
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: Timing Marks (Color Link) Of Timing Chain (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Timing Marks (Color Link) Of Timing Chain (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening torque :

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

Fig 8: Installing 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 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 9: Installing Timing Chain Auto Tensioner
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: TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain cover.
(Refer to "TIMING CHAIN COVER ")
Install cylinder head cover.
(Refer to "CYLINDER HEAD 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.