Repair procedures: Installation

[2.0 Non-BSM] 

1. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
2. Assemble the crankshaft sprocket on the crankshaft as the front mark on the crankshaft sprocket to be outward.
3. Tighten the oil pump tensioner bolt (A) after placing the tensioner spring on the dowel pin located in ladder frame, and then insert stopper pin to fix the tensioner (B).

   Tightening torque: 

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

   Fig 1: Identifying Oil Pump Tensioner & Bolt (2.0 Non-BSM)

   Courtesy of KIA MOTORS AMERICA, INC.
4. Assemble the oil pump chain on the crankshaft sprocket.
5. Assemble the oil pump assembly (C) on the ladder frame as placing oil pump sprocket in to oil pump.

   Tightening torque: 

   23.5 ~ 27.4N.m (2.4 ~ 2.8kgf.m, 17.4 ~ 20.2lb-ft)

   Fig 2: Identifying Bolts (2.0 Non-BSM)

   Courtesy of KIA MOTORS AMERICA, INC.
6. Install the oil pump chain guide (D) then remove the stopper pin.

   Tightening torque: 

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

[2.4 BSM] 

1. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
2. Confirm the balance shaft module timing mark.

   Timing marks to be visually aligned with centers of adjacent cast timing notches.

   Fig 3: Locating Timing Marks (2.4 BSM)

   Courtesy of KIA MOTORS AMERICA, INC.
3. Install balance shaft module that the timing mark of balance shaft module sprocket should be matched with the timing mark (color link) of balance shaft chain.

   Tightening torque: 

   16.7N.m (1.7kgf.m, 12.3lb-ft) + 60° + 60°

   Fig 4: Identifying Bolts (2.4 BSM)

   Courtesy of KIA MOTORS AMERICA, INC.

   Bolting order

   1. Assemble the bolts in order number as shown in Fig 5 with seating torque 25.5 N.m (2.6kgf.m, 18.8 lb-ft).
   2. Unfasten the bolts as reverse bolting order. (4-3-2-1)
   3. Assemble the bolts as specified bolting order in same increments as shown in Fig 5.
      Fig 5: Identifying Tightening Sequence Of Bolts (2.4 BSM)

      Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the balance shaft chain guide (C).

   Tightening torque: 

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

5. Install the balance shaft chain tensioner arm (B).

   Tightening torque: 

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

6. Install the balance shaft chain hydraulic tensioner (A) then remove the stopper pin.

   Tightening torque: 

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

   Fig 6: Identifying Balance Shaft Chain Hydraulic Tensioner, Arm, & Chain Guide (2.4 BSM)

   Courtesy of KIA MOTORS AMERICA, INC.
7. Confirm the timing marks.
8. Install the timing chain.

   (Refer to TIMING SYSTEM )