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Repair Procedures: Installation

  1. Install the jack to the upper oil pan.
    Fig 1: Locating Upper Oil Pan
    G06801459Courtesy of HYUNDAI MOTOR CO.
    NOTE: Place a rubber block between oil pan and jack.
  2. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
    Fig 2: Identifying Timing Mark On Timing Chain Cover And Key
    G06801460Courtesy of HYUNDAI MOTOR CO.
  3. Install the tensioner adapter assembly(A).
    Fig 3: Identifying Tensioner Adapter Assembly
    G06801461Courtesy of HYUNDAI MOTOR CO.
  4. Install the crankshaft sprocket(A) (LH camshaft drive).
    Fig 4: Identifying Crankshaft Sprocket
    G06801462Courtesy of HYUNDAI MOTOR CO.
  5. Install the LH timing chain guide (A) and the LH timing chain (B).

    Tightening torque 

    19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.2 ~ 18.1lb-ft)

    Fig 5: Identifying LH Timing Chain Guide (A) And LH Timing Chain (B)
    G06105084Courtesy of HYUNDAI MOTOR CO.
    CAUTION: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket ? Timing chain guide ? Exhaust CVVT sprocket ? Intake CVVT sprocket. The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
    Fig 6: Identifying Timing Mark On LH Camshafts
    G00510049Courtesy of HYUNDAI MOTOR CO.
    Fig 7: Identifying Timing Mark On Crankshaft Sprockets
    G00510050Courtesy of HYUNDAI MOTOR CO.
  6. Install the LH timing chain tensioner arm (B) and the chain tensioner(A).

    Tightening torque: 

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

    Tensioner arm (B): 18.8 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

    Fig 8: Identifying The LH Timing Chain Auto Tensioner (A) And LH Timing Chain Tensioner Arm(B)
    G00510051Courtesy of HYUNDAI MOTOR CO.
  7. Install the crankshaft sprocket(A) (O/P & RH camshaft drive).
    Fig 9: Identifying Crankshaft Sprocket
    G04879492Courtesy of HYUNDAI MOTOR CO.
  8. Install the oil pump sprocket(A) and the oil pump chain(B).

    Tightening torque 

    18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

    Fig 10: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
    G04879491Courtesy of HYUNDAI MOTOR CO.
  9. Install the RH timing chain guide(A) and the RH timing chain (B).

    Tightening torque 

    19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.2 ~ 18.1lb-ft)

    Fig 11: Identifying RH Timing Chain Guide (A) And RH Timing Chain (B)
    G06105079Courtesy of HYUNDAI MOTOR CO.
    CAUTION: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket ? Intake CVVT sprocket ? Exhaust CVVT sprocket. The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
    Fig 12: Identifying Timing Mark On LH Camshafts
    G00510048Courtesy of HYUNDAI MOTOR CO.
    Fig 13: Identifying Timing Mark On Sprockets
    G04879508Courtesy of HYUNDAI MOTOR CO.
  10. Install the RH timing chain tensioner arm(B) and the RH timing chain auto tensioner(A).

    Tightening torque: 

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

    Tensioner arm (B): 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

    Fig 14: Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
    G04879486Courtesy of HYUNDAI MOTOR CO.
  11. Install the oil pump chain guide(A).

    Tightening torque: 

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

    Fig 15: Locating Oil Pump Chain Guide(A)
    G04882972Courtesy of HYUNDAI MOTOR CO.
  12. Install the oil pump chain tensioner assembly(A).

    Tightening torque: 

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

    Fig 16: Locating Oil Pump Chain Tensioner Assembly(A)
    G04882971Courtesy of HYUNDAI MOTOR CO.
  13. Pull out the pins of hydraulic tensioner (LH & RH).
    Fig 17: Installing Set Pin After Compressing LH Timing Chain Tensioner
    G06105082Courtesy of HYUNDAI MOTOR CO.
    Fig 18: Identifying Pin Compressing Timing Chain Tensioner
    G04803492Courtesy of HYUNDAI MOTOR CO.
  14. Install the oil pump chain cover(A).

    Tightening torque 

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

    Fig 19: Locating Oil Pump Chain Cover(A)
    G04882970Courtesy of HYUNDAI MOTOR CO.
  15. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
    NOTE: Always turn the crankshaft clockwise.
    Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.
  16. 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 TB 1217H should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.

      3. Bead Width : 

      2.5mm(0.1in.)

      Fig 20: Identifying Sealant On Chain Cover
      G04879515Courtesy of HYUNDAI MOTOR CO.
    3. After applying liquid sealant TB1217H on 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.)

      NOTE:
      • Fill the T-joint area (6EA *) with sealant.
      • Apply sealant all around the dowel pin hole (2EA).
    4. Install the new gasket(A) to the timing chain cover.
      Fig 21: Identifying Timing Chain Cover Gasket
      G06801482Courtesy of HYUNDAI MOTOR CO.
      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.

      6. Tightening torque: 

      B(17) :

      18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft) C(4) :

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft) D(2) :

      58.8 ~ 68.8N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft) F(2) :

      24.5 ~ 26.5N.m (2.5 ~ 2.7kgf.m, 18.1 ~ 19.5lb-ft) G(4) :

      21.5 ~ 23.5N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.4lb-ft) H(1) :

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft) I(1) :

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft) J(1) :

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft) K(4) :

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft) L(1):

      21.6 ~ 26.5N.m (2.2 ~ 2.7kgf.m, 15.9 ~ 19.5lb-ft) - New bolt

      Fig 22: Identifying Dowel Pins On Cylinder Block And Holes On Timing Chain Cover
      G06105108Courtesy of HYUNDAI MOTOR CO.
    6. Connect the water vent hose.
    7. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
  17. Using SST(09231-3C100), install timing chain cover oil seal.
    Fig 23: Identifying SST (09231-3C100) On Timing Chain Cover
    G04879519Courtesy of HYUNDAI MOTOR CO.
  18. Install the crankshaft pulley(A).

    Tightening torque: 

    284.2 ~ 303.8N.m (29.0 ~ 31.0kgf.m, 209.8 ~ 224.2lb-ft)

    Fig 24: Identifying Crankshaft Damper Pulley
    G04879482Courtesy of HYUNDAI MOTOR CO.
    NOTE:

    There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.

    • Install the SST (flywheel stopper, 09231-3C300) to hold the ring gear after removing the starter.
      • Fig 25: Removing Crankshaft Pulley Using SST (Flywheel Stopper, 09231-3C300)
      G06801432Courtesy of HYUNDAI MOTOR CO.
    • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
      1. Remove the front muffler. (Refer to MUFFLER
      2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
        3. Fig 26: Locating Dust Cover At The Bottom Of The Upper Oil Pan
        G00510045Courtesy of HYUNDAI MOTOR CO.
      3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
      4. Fasten the two transaxle mounting bolts in the original mounted holes.
        5. Fig 27: Identifying Adjusting Holder Nuts (A) So That The Front Plate Of The Holder (B) Puts In The Ring Gear (C) Teeth
        G00510046Courtesy of HYUNDAI MOTOR CO.
      5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
        6. Fig 28: Identifying The SST (09231-3D100) With The Two Mounting Bolts
        G00510047Courtesy of HYUNDAI MOTOR CO.
  19. Install the drive belt auto tensioner(A).

    Tightening torque: 

    Bolt (B) :

    81.4 ~ 85.3N.m (8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft)

    Bolt (C) :

    17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)

    Fig 29: Identifying Drive Belt Auto Tensioner (A)
    G06105060Courtesy of HYUNDAI MOTOR CO.
  20. Install the drive belt idler(A).

    Tightening torque: 

    52.9 ~ 57.9N.m (5.4 ~ 5.9kgf.m, 39.1 ~ 42.7lb-ft)

    Fig 30: Identifying Drive Belt Idler
    G04879473Courtesy of HYUNDAI MOTOR CO.
  21. Install the power steering pump(A). (Refer INSTALLATION
    Fig 31: Identifying Power Steering Pump
    G04879470Courtesy of HYUNDAI MOTOR CO.
  22. Install the air conditioner compressor(A). (Refer to INSTALLATION
  23. Install the alternator(A).

    Tightening torque: 

    26.5 ~ 33.3N.m (2.7 ~ 3.4kgf.m, 19.5 ~ 24.6lb-ft)

    Fig 32: Identifying Air Conditioner Compressor (A)
    G06105057Courtesy of HYUNDAI MOTOR CO.

    Tightening torque 

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

    Fig 33: Identifying Alternator
    G06801487Courtesy of HYUNDAI MOTOR CO.
  24. 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.
    Fig 34: Identifying Drive Belt
    G06801493Courtesy of HYUNDAI MOTOR CO.
  25. Install the LH/RH cylinder head covers.
    NOTE:
    1. Install the cylinder head cover under the exhaust OCV cap is removed.
    2. To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover.

    Tightening torque 

    26.48 ~ 33.34N.m (2.7 ~ 3.4kgf.m, 19.53 ~ 24.59lb-ft)

    Fig 35: Identifying Alternator
    G06801487Courtesy of HYUNDAI MOTOR CO.
  26. Install the air conditioner compressor(A). (Refer to COMPRESSOR )
    Fig 36: Identifying Air Conditioner Compressor
    G06801488Courtesy of HYUNDAI MOTOR CO.
  27. Install the power steering pump(A). (Refer to HYDRAULIC POWER STEERING SYSTEM )
    Fig 37: Identifying Power Steering Pump
    G06801489Courtesy of HYUNDAI MOTOR CO.
  28. Lower the engine assembly by using the jack.
  29. Using SST(09231-3C100), install timing chain cover oil seal.
    Fig 38: Installing Timing Chain Cover Oil Seal Using SST(09231-3C100)
    G06801490Courtesy of HYUNDAI MOTOR CO.
  30. 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)

    Fig 39: Identifying Crankshaft Damper Pulley
    G06801491Courtesy of HYUNDAI MOTOR CO.
    Fig 40: Installing Crankshaft Damper Pulley Using SST(09231-3C300)
    G06801492Courtesy of HYUNDAI MOTOR CO.
  31. 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.

    Fig 41: Identifying Drive Belt
    G06801493Courtesy of HYUNDAI MOTOR CO.
  32. Install the LH/RH cylinder head covers.
    NOTE:
    • Install the cylinder head cover under the exhaust OCV cap is removed.
    • To prevent engine oil leakage, surely install the exhaust OCV cap after installing 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.)

      Fig 42: Identifying Sealant Applying Area On Timing Chain Cover
      G06801494Courtesy of HYUNDAI MOTOR CO.
    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 

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

      Fig 43: Identifying Cylinder Head Cover Bolts
      G06801495Courtesy of HYUNDAI MOTOR CO.
      CAUTION: Do not reuse cylinder head cover gasket.
    5. Install the exhaust OCV cap (A).

      6. Tightening torque 

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

      Fig 44: Locating The Exhaust Ocv Cap (A), And The LH, RH Cylinder Head Covers
      G00510042Courtesy of HYUNDAI MOTOR CO.
    6. Install the ignition coils.
    7. Connect the RH ignition coil connectors (A) and the injector connectors (B).
      Fig 45: Identifying RH Ignition Coil Connector (A) And Injector Connector (B)
      G06105046Courtesy of HYUNDAI MOTOR CO.
  33. Install the surge tank (A) and then connect the wiring connectors. (Refer to INTAKE SYSTEM AND EXHAUST SYSTEM

    Tightening torque 

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

    Fig 46: Identifying Surge Tank
    G00510038Courtesy of HYUNDAI MOTOR CO.
  34. Install the no. 1 engine mounting (A) through the lower position of A/C pipe line.

    Tightening torque 

    49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

    Fig 47: Identifying No. 1 Engine Mounting
    G06801407Courtesy of HYUNDAI MOTOR CO.
  35. Install the A/C pipe bracket mounting bolt (A).

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

    Fig 48: Identifying A/C Pipe Bracket Mounting Bolt
    G06801516Courtesy of HYUNDAI MOTOR CO.
  36. Install the engine coolant reservoir tank (A).

    37. Tightening torque 

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

  37. Install the engine mounting support bracket (C) and then connect the ground cable (B).

    Tightening torque 

    63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

    Fig 49: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
    G06801517Courtesy of HYUNDAI MOTOR CO.
  38. Install the transaxle mounting bolts(A).

    Tightening torque 

    49.03 ~ 63.74N.m (5.0 ~ 6.5kgf.m, 36.17 ~ 47.01lb-ft)

    Fig 50: Identifying Transaxle Mounting Bolts
    G06801518Courtesy of HYUNDAI MOTOR CO.
  39. Remove the jack from the upper oil pan.
    Fig 51: Locating Upper Oil Pan
    G06801519Courtesy of HYUNDAI MOTOR CO.
  40. Install the 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 TB 1217H should be applied on oil pan.

      The part must be assembled within 5 minutes after the sealant was applied.

      Bead width:  2.5mm(0.1in.).

      But marked area(*) to be 5.0mm(0.2in.)

      Fig 52: Identifying Liquid Sealant Applying Area On Lower Oil Pan
      G06801520Courtesy of HYUNDAI MOTOR CO.
      CAUTION:
      • Make clean the sealing face before assembling two parts.
      • Remove harmful foreign matters on the sealing face before applying sealant.
      • When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
      • To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
    3. Install the oil pan(A).

    Uniformly tighten the bolts in several passes.

    Tightening torque 

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

    Fig 53: Identifying Oil Pan
    G06801521Courtesy of HYUNDAI MOTOR CO.
  41. Install the upper radiator hose(A).
    Fig 54: Identifying Upper Radiator Hose
    G06801522Courtesy of HYUNDAI MOTOR CO.
  42. Install the side cover(A) and the RH front wheel.

    Tightening torque: 

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

    Wheel nuts : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

    Fig 55: Identifying RH Front Wheel Side Cover
    G06801523Courtesy of HYUNDAI MOTOR CO.
  43. Install the under cover(A).

    Tightening torque: 

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

    Fig 56: Identifying RH Front Wheel Under Cover
    G06801524Courtesy of HYUNDAI MOTOR CO.
  44. Install the air cleaner assembly.
    1. Install the air cleaner assembly (D) and then connect the AFS connector (C).

      2. Tightening torque: 

      7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

    2. Connect the ECM connectors (B).
    3. Connect the breather hose (A).
    4. Connect the AFS connector(A).
    Fig 57: Identifying AFS Connector, Breather Hose, Intake Air Hose And Air Cleaner
    G00510024Courtesy of HYUNDAI MOTOR CO.
  45. Install the air duct.
    Fig 58: Identifying Air Duct
    G06801526Courtesy of HYUNDAI MOTOR CO.
  46. Connect the negative terminal to the battery.
NOTE:
  • Refill engine oil.
  • Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
  • Inspect for fuel leakage.
  • After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  • Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
  • Refill radiator and reservoir tank with engine coolant.
  • Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
  • Turn Off the engine and let it cool down. 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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