Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new cylinder head and manifold gasket.
Always use new cylinder head bolts. Cylinder head bolts are torque - to - yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
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 assembly.
1. Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.
2. Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.
  
  Fig 1: Hardened Cylinder Block Hardened Sealant
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Refer to the illustration for applying sealant.
  
  Width:
  
  2.0 - 3.0 mm (0.0787 - 0.1181in.)
  
  Position:
  
  1.0 - 1.5 mm (0.0394 - 0.0591in.)
  
  Specification: TB 1217H or LOCTITE 5900H
  
  Fig 2: Locating Cylinder Head Gasket, Sealant And Cylinder Block Front Surface
  Courtesy of KIA MOTORS AMERICA, INC.
3. After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.
Place the cylinder head carefully not to damage the gasket.

Fig 3: Placing Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
Install the cylinder head bolts with washers.
1. Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.
  Tightening torque:
  
  29.4 N.m (3.0 kgf.m, 21.7 lb.ft) + 90° + 90°
  
  Fig 4: Cylinder Head Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Always use new cylinder head bolts. Cylinder head bolts are toque - to - yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Apply the engine oil to the journal before installing the cam shaft.
NOTICE
Install the intake & exhaust cam shaft (A).

Fig 5: Locating Intake And Exhaust Cam Shaft
Courtesy of KIA MOTORS AMERICA, INC.
Install the cam shaft bearing cap (A) in the order below.
Tightening torque

M6 bolts:

11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb.ft)

M8 bolts:

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb.ft)
Install the intake CVVT assembly (A) and the exhaust CVVT assembly (B).
Tightening torque:

63.7 - 73.5 N.m (6.5 - 7.5 kgf.m, 47.0 - 54.2 lb.ft)

NOTE: When installing the CVVT assembly, fix the cam shaft using wrench.

Fig 6: Fixing Cam Shaft Using Wrench
Courtesy of KIA MOTORS AMERICA, INC.
Install the cylinder head cover heat protector (A).
Tightening torque:

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

Fig 7: Locating Cylinder Head Cover Heat Protector
Courtesy of KIA MOTORS AMERICA, INC.
Install the rear engine hanger (A).
Tightening torque:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

Fig 8: Locating Rear Engine Hanger
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain.
(Refer to the Timing System - "TIMING CHAIN ")
Install other parts in the reverse order of removal.