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Home >> Kia Truck >> 2008 >> Sedona V6-3.8L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Timing System >> Repair Procedures >> 2 of 2

2 of 2

15. Install the RH timing chain auto tensioner (A).

Tightening torque :
9.80 - 11.76N.m(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





16. Install the RH cam-to-cam guide (A).

Tightening torque :
9.80 - 11.76N.m(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





17. Install the oil pump chain guide (A).

Tightening torque :
9.80 - 11.76N.m(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





18. Install the oil pump chain tensioner assembly (A).

Tightening torque :
9.80 - 11.76N.m(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





19. Pull out the pins of hydraulic tensioners (LH & RH).








20. Install the oil pump chain cover (A).

Tightening torque :
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





21. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

NOTE:
Always turn the crankshaft clockwise.

22. Install the timing chain cover.
(1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC.
(2) Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

Bead width : 2.5mm(0.1in.)





(3) After applying liquid sealant TB1217H on the timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.

Bead width : 2.5mm(0.1in.)





(4) Install the new gasket (A) to the timing chain cover.





NOTE:
During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.

(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 to be in exact position.

Tightening torque :
B(17) :18.62 - 21.56N.m (1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
C(4) :9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
D(1) :58.80 - 68.80N.m (6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
E(1) :58.80 - 68.80N.m (6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
F(2) :24.50 - 26.46N.m (2.5 - 2.7kgf.m, 18.08 - 19.53lb-ft)
G(4) :21.56 - 23.52N.m (2.2 - 2.4kgf.m, 15.91 - 17.36lb-ft)
H(1) :9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
I(1) :9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
J(1) :9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
K(4) :9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
L(1):21.56 - 26.46N.m (2.2 - 2.7kgf.m, 15.91 - 19.53lb-ft) - New bolt





(6) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
23. Install the water pump pulley (A).

Tightening torque :
7.84 - 9.80N.m(0.8 - 1.0kgf.m, 5.78 - 7.23lb-ft)





24. Install the drive belt auto tensioner (A).

Tightening torque :
Bolt(B):81.39 - 85.32N.m (8.3 - 8.7kgf.m, 60.03 - 62.93lb-ft)
Bolt(C):17.64 - 21.56N.m (1.8 - 2.2kgf.m, 13.02 - 15.91lb-ft)





25. Install the drive belt idler (A).

Tightening torque :
52.92 - 57.82N.m(5.4 - 5.9kgf.m, 39.06 - 42.67lb-ft)





26. Lower the engine assembly by using the jack.
27. Using SST (09231-3C100), install timing chain cover oil seal.




28. Using SST (09231-3C300) install the crankshaft damper pulley (A).

Tightening torque :
284.2 - 303.8N.m (29.0 - 31.0kgf.m, 209.76 - 224.22lb-ft)









29. Install the drive belt (A).
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S pump pulley-> tensioner pulley.
Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.




30. Install the cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2) After applying sealant (TB1217H), it should be assembled within 5 minutes.

Bead width: 2.5mm(0.1in.)





(3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(4) Install the cylinder head cover bolts as following method.

Tightening torque :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)






CAUTION:
Do not reuse cylinder head cover gasket.

(5) Install the ignition coil.
(6) Connect the RH ignition coil connector (A), the condenser connector (B) and install the wiring bracket (C).




(7) Install the connector bracket (A) to the LH cylinder head cover.




31. Install the surge tank and wiring connectors.
(1) Install the surge tank (A).

Tightening torque :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





(2) Install the connector bracket (A) to the surge tank.

Tightening torque :
6.86 - 10.78N.m (0.7 - 1.1kgf.m, 5.06 - 7.96lb-ft)





(3) Install the surge tank stay.

Tightening torque :
27.44 - 31.36N.m (2.8 - 3.2kgf.m, 20.25 - 23.14lb-ft)





(4) Connect the brake vacuum hose.
(5) Connect the PCV hose (C).
(6) Connect the water hoses (B) to the ETC.
(7) Install the ETC bracket (A).




(8) Connect the LH CMPS connector (A) and oil pressure switch connector(B).




(9) Install the wiring harness protector (E) and connect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D).




(10) Connect the LH front oxygen sensor connector (A).




(11) Connect the OCV connector (A) and knock sensor connector (B).




(12) Connect the ETC connector (A) and knock sensor connector (B).




(13) Connect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.




(14) Connect the RH injector connector (A) and ignition coil connector (B).




(15) Connect the RH oxygen sensor connector (A) and tighten the power steering hose mounting bolts (B).




32. Install the engine mounting bracket (A).

Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)





33. Install the coolant reservoir tank.
34. Remove the jack from the upper oil pan.
35. Install lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.

Bead width : 2.5mm(0.1in.).
But marked area(*) to be 5.0mm(0.2in.)






CAUTION:
1) Make clean the sealing face before assembling two parts.
2) Remove harmful foreign matters on the sealing face before applying sealant.
3) When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
4) To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

(3) Install the lower oil pan (A).

Tightening torque :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)





36. Install the side cover.

Tightening torque :
8.8 - 10.8N.m (0.9 - 1.1kgf.m, 6.5 - 7.9lb-ft)


37. Install the under cover (A).

Tightening torque :
8.8 - 10.8N.m (0.9 - 1.1kgf.m, 6.5 - 7.9lb-ft)





38. Install the RH front wheel.

Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)


39. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose and air cleaner assembly(C).
(2) Connect the breather hose (B) to the air intake hose.
(3) Connect the MAF sensor connector (A).




40. Install the engine cover (A).




41. Connect the battery negative cable (A).





NOTE:
- Refill engine with engine oil.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.

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