Repair Procedures: Installation

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 camshaft front bearing cap, cylinder head and cylinder block. The part must be assembled within 5 minutes of applying the sealant.

   Bead width:  2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)

   Fig 1: Sealant Locations On Chain Cover & On Counter Parts

   Courtesy of KIA MOTORS AMERICA, INC.
4. Apply liquid sealant Loctite 5900H or equivalent on the timing chain cover.

   The part must be assembled within 5 minutes of applying the sealant. Continuous bead of sealant should be applied to prevent any path of oil leakage.

   Bead width  : 2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)

   Fig 2: Applying Liquid Sealant Loctite 5900H Or Equivalent On Timing Chain Cover

   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 in exact position.

   Tightening torque 

   NOTE: M6 X 25 bolt:

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

   M8 X 28 bolt:

   18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

   Fig 3: Locating Timing Chain Cover With Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.

(Refer to "FRONT OIL SEAL ")

(Refer to "DRIVE BELT TENSIONER ")

1. If there is sign of leakage from inside the E-CVVT cover, replace it with a new one.
2. Check for worn connector brush.

   Specification:  Over 5 mm (0.1969 in.)

   Fig 6: Checking E-CVVT Cover

   Courtesy of KIA MOTORS AMERICA, INC.

   If measurement is below specification, replace the E-CVVT cover with a new one.

3. Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.
   Fig 7: Checking For Damaged Oil Seal

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4. After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.

Fig 8: Locating O-Ring

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1. Apply engine oil on oil seal lip (A).
   Fig 9: Locating Engine Oil Applying Area On Oil Seal Lip

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: When applying oil, keep the connector brush (A) clean from foreign materials.
   Fig 10: Locating Connector Brush

   Courtesy of KIA MOTORS AMERICA, INC.
2. Insert SST (09243-C1000) into the E-CVVT motor shaft.
   Fig 11: Inserting SST (09243-C1000) Into E-CVVT Motor Shaft

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Correctly mount SST onto the motor shaft.
3. Slowly push the E-CVVT cover (A) until it is flush with the timing chain cover surface.
   Fig 12: Pushing E-CVVT Cover

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Installing the E-CVVT cover without SST may cause oil leakage inside the E-CVVT motor due to damaged or separated E-CVVT oil seal.
4. Pre-tighten the bolts in the below sequence, and then remove the SST (09243-C1000).

   Tightening torque: 

   1.0 - 2.0 N.m (0.1 - 0.2 kgf.m, 0.7 - 1.4 lb.ft)

   Fig 13: Removing SST (09243-C1000)

   Courtesy of KIA MOTORS AMERICA, INC.
5. Tighten the bolts to the specified torque in the sequence below.

Tightening torque: 

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

Fig 14: E-CVVT Cover Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

1. By using SST (09243-C1000), insert the plug (A) into the E-CVVT cover hole.
   Fig 15: Inserting Plug Into E-CVVT Cover Hole Using SST (09243-C1000)

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Do not reuse a E-CVVT motor plug.
2. Mount the stopper of SST so that it sits at the end of E-CVVT motor shaft.
   Fig 16: Mounting Stopper Of SST

   Courtesy of KIA MOTORS AMERICA, INC.
3. Inspect the pressed depth of E-CVVT plug.
   1. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of motor shaft (1).
   2. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT plug (2).
      Fig 17: Inspecting Pressed Depth Of E-CVVT Plug

      Courtesy of KIA MOTORS AMERICA, INC.
   3. Calculate the pressed depth (3) of motor plug.

   If out of specification, reinstall after replacing the E-CVVT plug with a new one.

   Pressed depth: (3) =(2) -(1) 

   Specification:  1.9 - 2.1 mm (0.0748 - 0.0827 in.)

4. Insert the E-CVVT cover plug so that the protrusion (A) reaches the E-CVVT cover groove correctly.
   Fig 18: Locating Protrusion Of E-CVVT Cover

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 19: Inserting E-CVVT Cover Plug

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE:

   • Check how much protrude after installing the E-CVVT plug.
     Fig 20: Checking Plug Protrude Installation Dimensions

     Courtesy of KIA MOTORS AMERICA, INC.
   • Be careful that the plug is not inserted inside E-CVVT cover beyond the regulated range.
5. Install the engine support bracket (A).

   Tightening torque: 

   Bolt B: 4.0 ~ 4.5 kgf.m

   Bolt C: 2.0 ~ 2.5 kgf.m

   1. Temporarily install in the order of 1→2→3.
   2. Turn the bracket counterclockwise and install the bolt 1.
   3. Install in the order of 2→3→4→5→6.
   Fig 21: Engine Support Bracket Bolts Tightening Sequence

   Courtesy of KIA MOTORS AMERICA, INC.
6. Install the other parts in the reverse order of removal.