Timing belt replacement

Timing belt replacement - 1.5L & 1.6L - DOHC -2004 Kia Rio

Torque specifications: Ft. Lbs. (N.m)
Crankshaft Pulley Bolt 9-13 (12-17)
Crankshaft Sprocket Bolt 80-87 (108-118)
Timing Belt Guide Plate Bolt 9-13 (12-17)
Timing Belt Tensioner Pulley 28-38 (38-51)
Lock Bolt Water Pump Pulley Bolt 9-13 (12-17)

Timing Belt Cover Bolts
INCH Lbs. (N.m) 70-97 (8-11)

Timing belt replacement- 1.5L & 1.6L - DOHC -2004 Kia Rio

Removal and installation
Timing belt:

CAUTION:This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur.

Removal:
1.Disconnect negative battery cable. Loosen power steering lock bolts and nuts, and remove tension from power steering and air conditioning compressor drive belt. Remove power steering and air conditioning drive belt.

2.Loosen and remove generator bolts. Remove water pump pulley. Remove crankshaft pulley and timing belt guide plate. Remove upper and lower timing belt covers.

3.Turn crankshaft so that timing mark on crankshaft sprocket is aligned with timing mark on engine. Ensure "I" mark on intake camshaft sprocket is aligned with mark on cylinder head cover, and "E" mark on exhaust camshaft sprocket is aligned with mark on cylinder head cover.

CAUTION:DO NOT move camshaft or crankshaft once timing marks have been correctly positioned.

4.Loosen tension-er pulley lock bolt. While protecting timing belt with a rag, remove tension-er pulley. If belt is to be reused, mark direction of timing belt rotation for proper re-installation. Remove timing belt.

Inspection
Replace timing belt if it is contaminated with oil or grease. Check belt for wear, fraying or other damage. Inspect idler pulley and tension-er pulley for uneven wear and smooth bearing operation. Inspect
camshaft sprockets and crankshaft sprocket for broken teeth or damage.
NOTE: Replace tension-er spring whenever timing belt is replaced. Replace any component that shows damage or excessive wear.

Installation
1.Install tension-er pulley. Pull tension-er pulley to its furthest point, and tighten lock bolt. Check that timing mark on crankshaft sprocket is aligned with timing mark on engine.Ensure that camshaft sprockets are aligned with marks on cylinder head cover.

2.Install timing belt onto crankshaft sprocket first, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and finally, tension-er pulley. Ensure there is no looseness in belt between idler pulley and exhaust camshaft sprocket, or between intake and exhaust camshaft sprockets.

3.Loosen tension-er pulley lock bolt, and allow tension-er spring to apply tension to timing belt. Do not add additional tension. Tighten tension-er pulley lock bolt to specification..

4.Rotate crankshaft two full turns (clockwise only), and align timing mark on crankshaft sprocket with timing mark on engine block. Ensure that marks on camshaft sprockets align with marks on cylinder head cover.If marks do not align, remove timing belt and repeat process from tension-er installation.

5.Measure timing belt deflection by applying moderate pressure midway between camshaft sprockets. If deflection is not 0.39-0.50" (11-13 mm) with 22 lbs. (10 kg) of force applied, repeat installation process from tension-er installation. 6.Install lower and upper timing belt covers, timing belt guide plate and crankshaft pulley. Install water pump pulley. Tighten all bolts to specification.

7.Install generator belt and adjust tension. Install power steering and air conditioning drive belt, and adjust tension. Connect negative battery cable.

Ok here is a pic of what it should look like when they are installed. Hope this helps. Thanks.

The guide slots are pointed down best I can tell. Here is the only other pic I can find.

Generally the valves is the worst ! Check the piston tops and also after replacing the valves have the head pressure tested before replacement in vehicle !

TIMING BELT
Removal
Disconnect negative battery cable. Loosen power steering lock bolts and nuts, and remove tension from power steering and air conditioning compressor drive belt. Remove power steering and air conditioning drive belt.
Loosen and remove generator bolts. Remove water pump pulley. Remove crankshaft pulley and timing belt guide plate. Remove upper and lower timing belt covers.
Turn crankshaft so that timing mark on crankshaft sprocket is aligned with timing mark on engine.
Ensure "I" mark on intake camshaft sprocket is aligned with mark on cylinder head cover, and "E" mark on exhaust camshaft sprocket is aligned with mark on cylinder head cover. See Fig. 4.
CAUTION:DO NOT move camshaft or crankshaft once timing marks have been correctly positioned.

Loosen tensioner pulley lock bolt.

While protecting timing belt with a rag, remove tensioner pulley. If belt is to be reused, mark direction of timing belt rotation for proper reinstallation. Remove timing belt.

Installation
Install tensioner pulley. Pull tensioner pulley to its furthest point, and tighten lock bolt. Check that timing mark on crankshaft sprocket is aligned with timing mark on engine.
Ensure that camshaft sprockets are aligned with marks on cylinder head cover.
Install timing belt onto crankshaft sprocket first, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and finally, tensioner pulley.
Ensure there is no looseness in belt between idler pulley and exhaust camshaft sprocket, or between intake and exhaust camshaft sprockets.
Loosen tensioner pulley lock bolt, and allow tensioner spring to apply tension to timing belt. DO NOT add additional tension. Tighten tensioner pulley lock bolt to specification.

Rotate crankshaft two full turns (clockwise only), and align timing mark on crankshaft sprocket with timing mark on engine block.
Ensure that marks on camshaft sprockets align with marks on cylinder head cover.
If marks do not align, remove timing belt and repeat process from tensioner installation.
Measure timing belt deflection by applying moderate pressure midway between camshaft sprockets. If deflection is not 0.39-0.50" (11-13 mm) with 22 lbs. (10 kg) of force applied, repeat installation process from tensioner installation.
Install lower and upper timing belt covers, timing belt guide plate and crankshaft pulley. Install water pump pulley. Tighten all bolts to specification.

Install generator belt and adjust tension. Install power steering and air conditioning drive belt, and adjust tension. Connect negative battery cable.
Let me know

Refer to the belt routing diagrams site on this page. As far as TDC, when the #1 pistion is at TDC, the cam should be the farthest away from opening any valves as it can.

For what liter engine?

Put piston no.1 on its compression stroke/TDC then align cam and crank sprockets markings indicated it the repair manual-

Refer to the belt routing guides listed on this site.