This procedure covers replacement of the front crankshaft main seal on a 2015 Kia Forte 1.8L I4, requiring removal of timing cover and associated components.

Warnings

Tools required

Parts

• Front crankshaft main seal × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant (Hyundai/Kia approved) × 1 — Use OEM specification
• Engine oil and filter × 1 — 5W-20

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Allow engine to cool completely if recently operated
4. Raise and support front of vehicle securely on jack stands
5. Remove engine splash shield/undertray
6. Drain engine oil completely and remove oil filter
7. Install engine support bar across engine bay or attach engine hoist to lift eyes

Procedure

1. 1

   Remove accessory drive belt and components
   Release belt tensioner and remove serpentine accessory drive belt. Remove drive belt tensioner assembly mounting bolts. If equipped with A/C, unbolt A/C compressor and secure aside without disconnecting refrigerant lines. Remove power steering pump mounting bolts and secure pump aside without disconnecting hoses.
2. 2

   Remove crankshaft pulley
   Install crankshaft pulley holder tool to prevent crankshaft rotation. Using breaker bar or impact wrench, remove crankshaft pulley bolt (turns counterclockwise). This bolt is extremely tight at 180 Nm. Remove harmonic balancer/crankshaft pulley from crankshaft nose. Mark orientation if pulley has alignment features.
   ⚠Impact wrench is strongly recommended for this fastener. Do not attempt to hold crankshaft by placing transmission in gear as this can damage components.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

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

   Support engine and remove right side motor mount
   Ensure engine support bar or hoist is properly supporting engine weight. Remove right side engine mount bracket bolts from engine block and frame. Remove motor mount assembly to provide clearance for timing cover removal.
   ⚠️Verify engine is securely supported before removing mount bolts. Engine can shift suddenly causing injury or component damage.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
4. 4

   Disconnect lower radiator hose and drain coolant
   Position drain pan beneath lower radiator hose connection at engine. Loosen hose clamp and disconnect lower radiator hose from timing cover/water pump area. Allow coolant to drain into pan. Only the lower portion of coolant needs draining for this procedure.
5. 5

   Remove sensors and wiring from timing cover area
   Disconnect crankshaft position sensor electrical connector. Remove CKP sensor mounting bolt and carefully remove sensor from timing cover. Disconnect any other sensors or wiring harness brackets attached to timing cover. Label all connections for reassembly.
   Torque spec

   Sensor Bolts10 Nm (8 lb-ft)
6. 6

   Remove oil pan front bolts
   From underneath vehicle, remove the front section oil pan bolts that attach to timing cover (approximately 4-6 bolts). Do not remove entire oil pan. These bolts secure the oil pan to the timing cover and must be removed for cover separation.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
7. 7

   Remove timing cover bolts and cover
   Remove all timing cover bolts. There are two sizes: 10mm head bolts (torqued to 45 Nm) and 8mm head bolts (torqued to 25 Nm). Note bolt locations as they must be reinstalled in correct positions. Carefully separate timing cover from engine block using plastic pry points if present. Do not damage mating surfaces. Remove timing cover and old gasket material.
   ⚠Do not pry between metal sealing surfaces. Use designated pry points only to prevent warping the cover or damaging sealing surfaces.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
8. 8

   Remove old front crankshaft seal
   With timing cover removed from vehicle and placed on clean work surface, use seal removal tool or seal puller to carefully extract old front main seal from timing cover bore. Work evenly around seal to prevent cocking. Inspect seal bore for damage, scoring, or burrs that could damage new seal.
   ⚠Avoid scratching or gouging the seal bore in the timing cover. Any damage here will cause the new seal to leak.
9. 9

   Install new front crankshaft seal
   Clean seal bore thoroughly with degreaser and lint-free cloth. Lightly lubricate new seal lip with clean engine oil. Position new seal squarely in timing cover bore with spring side facing inward toward engine. Using appropriate size seal driver, carefully drive seal into bore until flush with cover surface. Ensure seal is installed evenly and fully seated.
   ⚠Seal must be installed perfectly square. Cocked installation will cause immediate oil leak and require seal replacement.
10. 10

    Prepare timing cover and mating surfaces
    Thoroughly clean all gasket material from timing cover and engine block mating surfaces using plastic gasket scraper. Clean oil pan mating surface on timing cover. Ensure all surfaces are completely clean, dry, and free of oil residue. Inspect crankshaft nose seal surface for grooves or damage; polish with fine emery cloth if minor imperfections exist.
11. 11

    Install timing cover with new gasket
    Install new timing cover gasket onto engine block locating pins if equipped, or position on cover. Apply thin bead of RTV silicone to oil pan-to-engine block junction areas as specified in service manual. Carefully install timing cover over crankshaft nose, ensuring seal lip is not damaged. Install all timing cover bolts hand-tight first. Tighten 10mm head bolts to 45 Nm (33 lb-ft) in proper sequence (typically center outward in crossing pattern). Tighten 8mm head bolts to 25 Nm (18 lb-ft) in sequence.
    ⚠Follow factory tightening sequence exactly to prevent cover warpage and ensure even gasket compression. Improper sequence will cause oil leaks.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Gasket Bolts19 Nm (14 lb-ft)
12. 12

    Reinstall oil pan front bolts and sensors
    Apply thin coat of RTV to oil pan mating surface if required by service manual. Install front section oil pan bolts and torque to 12 Nm (9 lb-ft). Reinstall crankshaft position sensor with new O-ring if equipped, torque sensor bolt to 10 Nm (8 lb-ft). Reconnect all sensor electrical connectors and wiring brackets.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Sensor Bolts10 Nm (8 lb-ft)
13. 13

    Install crankshaft pulley and accessories
    Clean crankshaft nose and pulley bore. Install crankshaft pulley/harmonic balancer onto crankshaft, aligning any keyways or alignment marks. Install crankshaft pulley bolt and tighten to 180 Nm (133 lb-ft) using torque wrench or impact wrench. Install power steering pump and A/C compressor to their mounting brackets and torque mounting bolts to 26 Nm (19 lb-ft) where applicable. Reinstall drive belt tensioner.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Mounting Bolts26 Nm (19 lb-ft)
14. 14

    Reinstall motor mount and reconnect cooling system
    Install right side motor mount and bracket. Torque mounting bolts to 45 Nm (33 lb-ft). Remove engine support equipment. Reconnect lower radiator hose and secure with clamp. Refill cooling system with Hyundai/Kia Long Life Green coolant to proper level. Install serpentine drive belt.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
15. 15

    Refill engine oil and complete final assembly
    Install new oil filter. Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft). Fill engine with 4.5 quarts of Kia Genuine 5W-20 engine oil. Reinstall engine splash shield/undertray. Lower vehicle. Reconnect negative battery cable.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in proper sequence
2. Double-check all electrical connectors are fully seated
3. Verify drive belt is properly routed and tensioned
4. Allow RTV silicone to cure for minimum time specified by manufacturer before starting engine (typically 1 hour)

Verification

• Check engine oil level on dipstick and adjust to full mark
• Check coolant level in reservoir and top off as needed
• Start engine and verify no oil leaks from timing cover area
• Check for coolant leaks at lower radiator hose connection
• Verify no abnormal noises from front of engine
• Allow engine to reach operating temperature and recheck for leaks
• Check engine oil level again after test drive and top off if needed

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