Timing Belt: Installation

Install the camshaft sprocket and tighten the bolt to the specified torque.
1. Temporarily install the camshaft sprocket bolt (C).
2. Hold the portion (A) of the camshaft with a hexagonal wrench, and tighten the bolt (C) with a wrench (B).
  Tightening torque: 98.1-117.7 N.m (10-12 kg-m, 72.3-86.8 lb-ft)
  
  Fig 1: Installing Camshaft Sprocket
  Courtesy of KIA MOTORS AMERICA, INC.
Install the cylinder head cover.
1. Install the cylinder head cover (A) and bolts (B).
  Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)
  
  Fig 2: Installing Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the PCV (Positive Crankcase Ventilation) hose (A) and breather hose (B) to the cylinder head cover.
  
  Fig 3: Installing PCV Hose & Breather Hose To Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the accelerator cable (A) to the cylinder head cover.
  
  Fig 4: Installing Accelerator Cable
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the spark plug cables.
  
  Fig 5: Installing Spark Plug Cables
  Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft sprocket (A).

Fig 6: Installing Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
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 7: Aligning Camshaft Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.

Fig 8: Aligning Crankshaft Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler pulley (A) and tighten the bolt (B) to the specified torque.
Tightening torque: 42.2-53.9 N.m (4.3-5.5 kg-m, 31.1-39.8 lb-ft)

Fig 9: Installing Idler Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Temporarily install the timing belt tensioner (A) with plain washer (B).

Fig 10: Temporarily Installing Timing Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing belt on pulleys. See Fig 11.
Crankshaft sprocket (A) --> idler pulley (B) --> camshaft sprocket (C) --> timing belt tensioner (D).

Fig 11: Illustrating Timing Belt Installation Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Temporarily install tensioner pulley using center bolt to add tension force to the belt.
Adjust the timing belt tension.
1. Rotate the crankshaft clockwise (view from front) through angle equivalent to two teeth (18°) of camshaft sprocket (A).
  
  Fig 12: Rotating Crankshaft
  Courtesy of KIA MOTORS AMERICA, INC.
2. Using a hex-wrench, apply tension to the timing belt in the clockwise direction so that there is no slack in the belt on the tension side.
  
  Fig 13: Applying Tension To Timing Belt
  Courtesy of KIA MOTORS AMERICA, INC.
3. Tighten the tensioner bolt.
  Tightening torque: 42.2-53. 9 N.m (4.3-5.5 kg-m, 31.1-39.8 lb-ft)
4. Recheck the belt tension. When the tension side of timing belt is pushed horizontally with a moderate force [approx. 2 kg (20N, 5 lb)], the timing belt cog end sags in approx. 4-6 mm (0.16-0.24 in).
  
  Fig 14: Measuring Timing Belt Tension
  Courtesy of KIA MOTORS AMERICA, INC.
Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.
Install the timing belt lower cover (A) with 5 bolts (B).
Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)

Fig 15: Installing Timing Belt Lower Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the flange and crankshaft pulley (A), and then tighten crankshaft pulley bolt (B). Make sure that the crankshaft sprocket pin fits into the small hole in the pulley.
Tightening torque: 166.7-176.5 N.m (17-18 kg-m, 123.0-130.2 lb-ft)

Fig 16: Installing Flange & Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the front upper cover.
Tightening torque: 7.8-9.8 N.m (0.8-1.0 kg-m, 5.8-7.2 lb-ft)

Fig 17: Installing Front Upper Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley and 4 bolts.
Install the power steering pump drive belt. See CHECKING POWER STEERING BELT TENSION .
Install the air conditioner compressor drive belt. See DRIVE BELT .
Install the alternator drive belt. See ALTERNATOR BELT INSPECTION & ADJUSTMENT .
Tighten the bolts of water pump pulley.
Install the engine mounting support bracket.
1. Install the engine mounting support bracket stay plate (A) with bolt (B).
  Tightening torque: 42.2-53.9 N.m (4.3-5.5 kg-m, 31.1-39.8 lb-ft)
  
  Fig 18: Installing Engine Mounting Support Bracket Stay Plate
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the engine mounting support bracket (A) with nuts (C, D) and bolt (B).
  Tightening torque:
  
  Nut (D): 68.6-93.2 N.m (7.0-9.5 kg-m, 50.6-68.7 lb-ft)
  
  Nut (C) and bolt (B): 49.0-63.7 N.m (5.0-6.5 kg-m, 36.2-47.0 lb-ft)
  
  Fig 19: Installing Engine Mounting Support Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
Install the RH side cover (A) with 2 bolts (B).

Fig 20: Installing RH Side Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Tightening torque: 88.3-98.1 N.m (9.0-10.0 kg-m, 65.1-72. 3 lb-ft)
Install the engine cover with bolts.
Tightening torque: 3.9-5.9 N.m (0.4-0.6 kg-m, 2.9-4.3 lb-ft)

Fig 21: Installing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.