Camshaft R&R

Complete removal and replacement of the intake and exhaust camshafts on the 2015 Kia Forte 1.8L I4, including timing chain removal and valve train disassembly.

Warnings

Tools required

Parts

• Intake camshaft × 1 — Use OEM specification
• Exhaust camshaft × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Camshaft seals × 2 — Use OEM specification
• Timing chain tensioner × 1 — Use OEM specification
• Timing chain guide (if worn) × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification

Fluids

• Kia Genuine 5W-20 engine oil — 4.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 1 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable and secure away from terminal
3. Remove engine cover by pulling upward on clips
4. Drain engine oil completely and replace drain plug with new crush washer
5. Drain coolant from radiator drain valve into appropriate container
6. Remove air intake duct and air cleaner assembly
7. Disconnect all electrical connectors from valve cover (ignition coils, VVT solenoid, camshaft position sensors)
8. Remove ignition coil pack assemblies
9. Label and photograph all vacuum lines and electrical connections
10. Support engine from below with jack and wood block under oil pan
11. Remove right-side engine mount to provide clearance for timing cover access

Procedure

1. 1

   Remove valve cover
   Remove all valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover off cylinder head. If stuck, gently tap with rubber mallet - do not pry. Clean all gasket material from mating surfaces using plastic scraper. Inspect PCV valve and breather system while exposed.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
2. 2

   Remove accessory drive belt and crankshaft pulley
   Rotate tensioner clockwise to release belt tension and remove accessory drive belt. Use crankshaft pulley holding tool to prevent rotation. Remove crankshaft pulley bolt (may require breaker bar or impact wrench). Remove harmonic balancer/crankshaft pulley from crankshaft nose. Note position of any alignment dowels.
   ⚠Crankshaft pulley bolt is very tight. Ensure holding tool is secure before applying force to prevent engine rotation.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing chain cover
   Disconnect crankshaft and camshaft position sensor connectors. Remove sensor mounting bolts and withdraw sensors from timing cover. Remove all timing cover bolts, noting different lengths and positions (8mm and 10mm bolts). Carefully separate timing cover from cylinder block - may require gentle tapping with rubber mallet. Clean all RTV sealant from mating surfaces on both block and cover.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)

   Crankshaft Position Sensor10 Nm (7 lb-ft)

   Camshaft Position Sensor10 Nm (7 lb-ft)
4. 4

   Mark and verify timing alignment
   Rotate crankshaft to TDC (Top Dead Center) cylinder #1 compression stroke. Verify timing marks on crankshaft sprocket and camshaft sprockets align with marks on engine block and cylinder head. Use paint marker or scribe to mark timing chain links that align with sprocket timing marks. Photograph all timing marks and chain positions for reference. Mark relationship between chain and both camshaft sprockets with paint pen.
   ⚠️This is the most critical step. Incorrect timing marks will result in engine damage upon startup. Triple-check all alignments.
5. 5

   Remove timing chain tensioner and guides
   Remove timing chain tensioner mounting bolt. Carefully withdraw tensioner - note the spring-loaded plunger position. Remove timing chain guide bolts and remove fixed chain guides. Inspect guides for wear grooves or cracks - replace if any damage is visible. Keep all hardware organized by location.
   ⚠Tensioner is spring-loaded. Control removal to prevent it from shooting out.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
6. 6

   Remove camshaft sprockets and timing chain
   Hold each camshaft with wrench on hex section to prevent rotation. Remove intake and exhaust camshaft sprocket bolts and cam phaser bolt. Note that cam phaser (VVT) is on intake camshaft. Carefully lift off sprockets while supporting timing chain. Remove timing chain from crankshaft sprocket. If equipped, remove timing chain idler sprocket. Inspect chain for wear, stretching, or damaged links.
   ⚠Never allow camshafts to rotate once sprockets are removed. This will change valve positions relative to pistons.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Cam Phaser Bolt65 Nm (48 lb-ft)

   Timing Chain Idler Sprocket25 Nm (18 lb-ft)
7. 7

   Remove camshaft bearing caps
   Loosen all camshaft bearing cap bolts gradually in reverse sequence (outward from center in multiple passes, 1-2 turns at a time) to prevent warping. Keep caps in exact order - they are numbered and directional. Remove bearing caps and store with their respective bolts. Note arrow marks on caps indicating front of engine. Inspect bearing surfaces in caps and cylinder head for scoring or wear.
   ⚠️Never remove bearing caps all at once or in random order. Uneven release of valve spring pressure can warp cylinder head or damage caps.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
8. 8

   Remove camshafts
   Carefully lift intake camshaft straight up and out of cylinder head. Repeat for exhaust camshaft. Handle camshafts carefully to avoid damaging bearing journals or cam lobes. Place on clean, padded surface where they cannot roll. Note orientation of camshafts (intake vs exhaust are different). Inspect all bearing journals for scoring, wear, or discoloration.
   ⚠Do not rest camshafts directly on cam lobes - this can cause damage. Support on bearing journals only.
9. 9

   Inspect and prepare for installation
   Thoroughly clean all bearing surfaces in cylinder head with lint-free cloth and brake cleaner. Inspect cylinder head bearing bores for scoring or damage. Clean camshaft journals with solvent and dry completely. Apply clean engine oil to all bearing surfaces in cylinder head. Lubricate new camshaft bearing journals with assembly lube or clean engine oil. Verify camshaft specifications (lobe height, journal diameter, runout) if reusing old camshafts.
   ℹ️Any contamination in bearing surfaces will cause rapid wear and failure. Cleanliness is critical.
10. 10

    Install camshafts
    Carefully lower intake camshaft into position in cylinder head, ensuring it seats fully in bearing bores. Install exhaust camshaft in same manner. Verify camshafts rotate freely by hand. Apply clean engine oil to all bearing cap surfaces. Install bearing caps in original positions with arrow marks pointing to front of engine. Hand-start all cap bolts before tightening any.
    ⚠Ensure camshaft lobes are positioned to minimize valve spring pressure during cap installation. Consult service manual for recommended cam positions.
11. 11

    Torque camshaft bearing caps
    Tighten camshaft bearing cap bolts in sequence from center outward in at least 3 progressive passes. First pass: hand-tight. Second pass: 7 Nm (5 lb-ft). Third pass: final torque of 14 Nm (10 lb-ft). Verify camshafts rotate smoothly by hand after torquing. Check that camshaft end play is within specification (0.1-0.2mm typical) using dial indicator.
    ⚠️Incorrect torque sequence or values will cause bearing failure. Follow center-outward pattern strictly and use multiple passes.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
12. 12

    Install timing chain and sprockets
    Install crankshaft sprocket if removed. Route timing chain over crankshaft sprocket and around both camshaft positions. Align timing marks on camshafts with TDC position. Install camshaft sprockets onto camshafts, aligning chain marks made during removal with sprocket timing marks. Install cam phaser on intake camshaft. Apply medium-strength threadlocker to cam phaser bolt threads. Hold camshafts with wrench on hex sections and torque sprocket bolts and cam phaser bolt to specification.
    ⚠️Triple-verify timing mark alignment before torquing sprockets. Incorrect timing will cause immediate engine damage on startup.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Cam Phaser Bolt65 Nm (48 lb-ft)
13. 13

    Install timing chain guides and tensioner
    Install timing chain fixed guides and torque guide bolts to specification. Compress new timing chain tensioner plunger and lock with pin or clip. Install tensioner and torque bolt to specification. Remove locking pin/clip to apply tension to chain. Manually rotate crankshaft 2 complete revolutions clockwise and verify all timing marks realign perfectly at TDC. Check chain tension and guide contact.
    ⚠️After rotating engine 2 revolutions, timing marks MUST realign exactly. If not, remove chain and reinstall correctly.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
14. 14

    Install timing cover
    Clean all mating surfaces thoroughly. Apply thin bead of RTV silicone to timing cover sealing surface - do not use excessive sealant. Install new camshaft and crankshaft seals into timing cover using seal driver. Position timing cover carefully onto engine block, ensuring proper alignment with dowel pins. Install all timing cover bolts hand-tight first, then torque 8mm bolts to 25 Nm and 10mm bolts to 45 Nm in proper sequence (typically center outward, alternating sides). Install crankshaft and camshaft position sensors with new O-rings.
    ⚠Allow RTV sealant to cure for at least 30 minutes before adding oil. Do not start engine for at least 2 hours.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Crankshaft Position Sensor10 Nm (7 lb-ft)

    Camshaft Position Sensor10 Nm (7 lb-ft)
15. 15

    Install crankshaft pulley and valve cover
    Install crankshaft pulley/harmonic balancer onto crankshaft nose, aligning keyway. Use holding tool and torque crankshaft pulley bolt to 180 Nm (133 lb-ft). Install new valve cover gasket onto valve cover. Apply small dab of RTV at front camshaft cap corners. Position valve cover and install bolts, torquing in sequence from center outward to 10 Nm (7 lb-ft). Install ignition coils, VVT solenoid, and all electrical connectors.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Cover Bolts15 Nm (11 lb-ft)

    VVT Solenoid Bolt10 Nm (7 lb-ft)

Reassembly

1. Reinstall right-side engine mount and torque mounting bolts to specification
2. Install accessory drive belt following routing diagram on belt tensioner
3. Reinstall air intake system and engine cover
4. Refill engine with 4.5 quarts of Kia Genuine 5W-20 oil using new oil filter
5. Refill cooling system with Hyundai/Kia Long Life Coolant (Green) - approximately 1 quart lost during procedure
6. Reconnect negative battery cable
7. Bleed cooling system by running engine with heater on until thermostat opens

Verification

• Before starting engine, manually rotate crankshaft 4 complete revolutions by hand and verify no binding or resistance - if any resistance is felt, stop immediately and investigate
• Verify all timing marks still align correctly after manual rotation
• Start engine and listen for any abnormal valvetrain noise - ticking, rattling, or knocking indicates timing or bearing problem
• Check for oil leaks around valve cover and timing cover after 5 minutes of running
• Monitor oil pressure gauge - pressure should be normal within 10 seconds of startup
• Verify check engine light does not illuminate for camshaft position sensor codes (P0340, P0341, P0345, P0346)
• Allow engine to reach operating temperature and verify smooth idle with no misfires
• Test drive vehicle and verify normal power delivery and no hesitation or rough running
• Recheck oil level after test drive and top off if necessary
• Inspect for any coolant or oil leaks 24 hours after completion

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