Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

Install the tensioner adapter (A) and the timing chain guide bolts (B).
Tightening torque:

Tensioner adapter bolts:

21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)

Timing chain guide bolts:

21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)

Fig 1: Identifying Tensioner Adapter And Timing Chain Guide Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft sprocket (A) with the friction plates (B).
NOTE: Completely fix the four friction plate clips and the sprocket groove.
Align the key-home of the friction plate with the key-home of the sprocket.
Be careful for the clip not to be folded.
The block is placed at bottom up before install the timing chain system and timing chain cover assembly.

Fig 2: Identifying Crankshaft Sprocket And Friction Plates
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: The mark of friction plate should be placed top. (Engine is placed bottom up)
Install the oil pump chain (C) with the oil pump sprocket (B) and oil pump chain tensioner (A).
Tightening torque:
1. 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. 21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)
  
  Fig 3: Identifying Oil Pump Chain, Sprocket And Chain Tensioner
  Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain with the timing chain tensioner arm (A), the timing chain guide (B) and the timing chain locking tool (SST: 09231-2J600) (C).
Tightening torque:

Timing chain tensioner arm bolts:

21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)

Fig 4: Installing Timing Chain Using Timing Chain Tensioner Arm, Guide And Locking Tool (1 Of 2)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 5: Installing Timing Chain Using Timing Chain Tensioner Arm, Guide And Locking Tool (2 Of 2)
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Align the timing mark of the friction plate and crankshaft sprocket.

Fig 6: Identifying Timing Mark On Friction Plate And Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain lower cover (A).
NOTE: Assemble the timing chain lower cover with engine bottom up condition.
1. The sealant locations on chain lower cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
2. Install the new gasket (A) to the timing chain lower cover.
  
  Fig 7: Identifying Timing Chain Lower Cover
  Courtesy of HYUNDAI MOTOR AMERICA
3. Apply liquid sealant LT 5900H or equivalent on timing chain lower cover. The part must be assembled within 5 minutes after sealant was applied.
  Sealant should be applied in a continuous beed in each of the areas indicated below.
  
  Bead width: Ø2.5 ± 0.5mm
  
  Fig 8: Identifying Liquid Sealant Applying Areas On Timing Chain Lower Cover (1 Of 2)
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 9: Identifying Liquid Sealant Applying Areas On Timing Chain Lower Cover (2 Of 2)
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - During timing chain lower cover installation, care not to take off applied sealant on the timing chain lower cover by contact with other parts.
  - Apply sealant in a 4.0 ± 0.5mm wide spot for the 4 T-joints (D).
4. The dowel pins on the cylinder block and holes on the timing chain lower cover should be used as a reference in order to assemble the timing chain lower cover to be in exact position.
  Tightening torque:
  
  23.5 ~ 27.5N.m (2.4 ~ 2.8kgf.m, 17.4 ~ 20.3lb-ft)
  
  [Front]
  
  Fig 10: Identifying Timing Chain Lower Cover (Front)
  Courtesy of HYUNDAI MOTOR AMERICA
  
  [Rear]
  
  Fig 11: Identifying Timing Chain Lower Cover (Rear)
  Courtesy of HYUNDAI MOTOR AMERICA
5. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the cylinder head assembly. (Refer to CYLINDER HEAD assembly in this group)
NOTE: Before install the cylinder head assembly, place the engine up right.
Install the camshaft assembly. (Refer to CYLINDER HEAD assembly in this group)
Remove the SST from the timing chain guide and the timing chain tensioner arm.
Install the timing chain to the camshaft sprocket. (Refer to CYLINDER HEAD assembly in this group)

Fig 12: Identifying Timing Chain On Camshaft Sprocket
Courtesy of HYUNDAI MOTOR AMERICA

Fig 13: Identifying Timing Mark On Camshaft Sprocket (1 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 14: Identifying Timing Mark On Camshaft Sprocket (2 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 15: Identifying Timing Mark On Camshaft Sprocket (3 Of 3)
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket → Intake camshaft sprocket. (LH Bank)
Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket. (RH Bank)
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain during installation.
Install the timing chain tensioner. (Refer to CYLINDER HEAD assembly in this group)
Tightening torque:

78.5 ~ 88.3N.m (8.0 ~ 9.0kgf.m, 57.9 ~ 65.1lb-ft)
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.
Install the O-ring to the water temperature control assembly (A).

Fig 16: Identifying Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the water temperature control assembly (A).
Tightening torque:

16.7 ~ 19.6N.m (1.7 ~ 2.0kgf.m, 12.3 ~ 14.5lb-ft)

Fig 17: Identifying Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump (A).
Tightening torque:

19.6 ~ 24.5Nm (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

Fig 18: Identifying Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Using SST (09231-2J300, 09231-H1100), Install the front oil seal (A).

Fig 19: Installing Front Oil Seal Using SST (09231-2J300 And 09231-H1100)
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft pulley (A).
Tightening torque:

392.3~ 402.1Nm (40.0~41.0kgf.m, 289.3~ 296.6lb-ft)

Fig 20: Identifying Crankshaft Pulley
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Use the SST (flywheel stopper, 09231-2B100) to Install the crankshaft pulley bolt, after remove the starter.

Fig 21: Installing Crankshaft Pulley Bolt Using SST (09231-2B100)
Courtesy of HYUNDAI MOTOR AMERICA
Install the upper oil pan.
1. Using a gasket scraper, remove all the old gasket material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant LT 5900H or TB1217 should be applied on upper oil pan. The part must be assembled within 5 minutes after the sealant was applied.
  Bead width: 2.5mm (0.1in)
  
  Fig 22: Identifying Upper Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - Clean the sealing face before assembling two parts.
  - Remove harmful foreign materials on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not protrude 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 upper oil pan.
  
  Fig 23: Identifying Upper Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 24: Identifying Upper Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
Install the lower oil pan.
1. Using a gasket scraper, remove all the old gasket material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB1217H or LT5900H should be applied on lower oil pan. The part must be assembled within 5 minutes after the sealant was applied.
  Bead width: 2.5mm (0.1in)
  
  Fig 25: Identifying Liquid Sealant Applying Areas On Lower Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - Clean the sealing face before assembling two parts.
  - Remove harmful foreign materials on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not protrude 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 lower oil pan.
  
  Fig 26: Identifying Lower Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 27: Identifying Lower Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
Install the oil filter & cooler assembly (B).
Tightening torque:

19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

Fig 28: Identifying Oil Filter & Cooler Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt tensioner (A).
Tightening torque:

19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

Fig 29: Identifying Drive Belt Tensioner
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A).
Tightening torque:

18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

NOTE: Tighten every bolt diagonally.

Fig 30: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt idler (A).
Tightening torque:

37.3 ~ 41.2Nm (3.8 ~ 4.2kgf.m, 27.5 ~ 30.4lb-ft)

Fig 31: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR AMERICA
Install the air conditioner compressor (A). (Refer to INSTALLATION .

Fig 32: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator bracket (A).
Tightening torque:

Bolts (B) 4EA:

29.4 ~ 41.2N.m (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft)

Bolt (C) 1EA:

19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

Fig 33: Identifying Alternator Bracket And Mounting Bolts (1EA And 4EA)
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator (A). (Refer to REPLACEMENT .
Tightening torque:

29.4 ~ 41.2N.m (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft)

Fig 34: Identifying Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Install the removed parts. (Refer to CYLINDER HEAD assembly installation procedure in this group)