Repair Procedures: Installation

NOTE:

Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
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.
1. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
2. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Fig 1: Identifying Sealant Applying Area On Cylinder Head And Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Refer to below illustration to apply the sealant.
  
  Bead width: 2.0~3.0 mm
  
  Sealant locations: 1.0~1.5 mm from block surface
  
  Recommended sealant: Liquid sealant TB1217H
  
  Fig 2: Identifying Sealant Applying Area On Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
3. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Fig 3: Identifying Sealant Applying Area On Cylinder Head Gaskets
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Be careful of the installation direction.
  
  Fig 4: Identifying Number On Cylinder Head Gasket
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the cylinder head.
  NOTE: Remove the extruded sealant after assembling cylinder heads.
  
  Fig 5: Identifying Cylinder Head
  Courtesy of KIA MOTORS AMERICA, INC.
Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
Install cylinder head bolts.
1. Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
2. Using SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
  Tightening torque
  
  Head bolt: 37.3 ~ 41.2 Nm (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + 118 ~ 122° + 88 ~ 92°
  
  Bolt (A): 18.62 ~ 23.52 Nm (1.9 ~ 2.4 kgf.m, 13.74 ~ 17.36 lb-ft)
  
  NOTE: Always use new cylinder head bolt.
  
  Fig 6: Cylinder Head Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 7: Identifying Cylinder Head Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 8: Tightening Cylinder Head Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
Install the CVVT and camshaft sprocket.
Tightening torque

64.68 ~ 76.44 Nm (6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4 lb-ft)

Fig 9: Identifying CVVT And Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Install camshaft-inlet to dowel pin of CVVT assembly.
  At this time, attend not to be installed to oil hole of camshaft-inlet.
- Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
- Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.

Install camshafts (A).

NOTE:

Apply a light coat of engine oil on camshaft journals.
Assemble the key groove of camshaft rear side to the same level of head top surface.
Be careful the right, left bank, intake, exhaust side before assembling.

Fig 10: Identifying Camshafts
Courtesy of KIA MOTORS AMERICA, INC.

Intake camshaft

Fig 11: Identifying Intake Camshaft

Courtesy of KIA MOTORS AMERICA, INC.

INTAKE CAMSHAFT REFERENCE

	LH	RH
3.3L	A: Ø27 mm (1.0630 in.)	A: Ø30 mm (1.1811 in.)
3.3L	B: Ø27 mm (1.0630 in.)	B: Ø30 mm (1.1811 in.)
3.8L	A: Ø30 mm (1.1811 in.)	A: Ø27 mm (1.0630 in.)
3.8L	B: Ø27 mm (1.0630 in.)	B: Ø30 mm (1.1811 in.)

Exhaust camshaft

Fig 12: Identifying Exhaust Camshaft

Courtesy of KIA MOTORS AMERICA, INC.

EXHAUST CAMSHAFT REFERENCE

	LH	RH
3.3L/3.8L	A: Ø27 mm (1.0630 in.)	A: Ø30 mm (1.1811 in.)

Fig 13: Identifying Exhaust Camshaft

Courtesy of KIA MOTORS AMERICA, INC.

EXHAUST CAMSHAFT REFERENCE

	LH	RH
3.3L	A: Ø30 mm (1.1811 in.)	A: Ø30 mm (1.1811 in.)
3.3L	B: Ø27 mm (1.0630 in.)	B: Ø27 mm (1.0630 in.)
3.8L	A: Ø30 mm (1.1811 in.)	A: Ø30 mm (1.1811 in.)
3.8L	B: Ø27 mm (1.0630 in.)	B: Ø27 mm (1.0630 in.)

Install camshaft bearing caps with the order below.
Tightening torque

1st step: 5.9 Nm (0.6 kgf.m, 4.3 lb-ft)

2nd step: 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

Fig 14: Camshaft Bearing Caps Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful the right, left bank, intake, exhaust side before assembling.

Fig 15: Identifying Right, Left Bank, Intake And Exhaust Side Assembly
Courtesy of KIA MOTORS AMERICA, INC.
1. L (LH), R (RH)
2. I (Intake), None (Exhaust)
3. Journal number
4. Front mark
  CAUTION: Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10 mm (0.3937 in.) from the top of cylinder block.
Install water temperature control assembly.
Install timing chain.
Check and adjust valve clearance.
Install the exhaust manifold.
Install the intake manifold.