Repair Procedures: Installation

Dowel pin of crankshaft should be positioned at 3° in relation to vertical center line.

Fig 1: Positioning Dowel Pin Of Crankshaft At 3° In Relation To Vertical Center Line
Courtesy of HYUNDAI MOTOR AMERICA
Align the TDC marks (A) of the CVVT sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.

Fig 2: Aligning TDC Marks Of CVVT Sprockets With Upper Surface Of Cylinder Head
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Install the new O-rings (A).

Fig 3: Locating O-Rings
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Install the timing chain guide (A) and the timing chain (B).
Tightening torque:

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

Fig 4: Locating Timing Chain Guide And Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
Order: Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket.
Install the chain tensioner arm (A).
Tightening torque:

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

Fig 5: Locating Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR AMERICA
Install the hydraulic tensioner (A) and remove the pin (B).
Tightening torque:

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

Fig 6: Locating Hydraulic Tensioner And Pin
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Recheck the top dead center (TDC) marks on the crankshaft and camshaft.
Install the timing chain cover.
1. Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
2. Apply the liquid gasket (TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.
  Width : 3 ~ 5 mm (0.1181 ~ 0.1969 in.)
3. Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts (A) of the timing chain cover and Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the rest parts (B). Reassemble the cover within 5 minutes.
  Width : 3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
  
  Fig 7: Applying Liquid Gasket On Water Pump Contact Parts Of Timing Chain Cover
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Remove oil or dust on the surface surely.
4. Align the dowel pin of the cylinder block and the holes of the oil pump.
5. Tighten the bolts to install the timing chain cover (A).
  Tightening torque :
  
  M8 bolts:
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  M6 bolts:
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 8: Locating Timing Chain Cover With Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: After the installation, do not crank engine or apply pressure on the cover for half an hour.
Using the SST (09455-21200), reassemble the timing chain cover oil seal.

Fig 9: Reassembling Timing Chain Cover Oil Seal Using SST (09455-21200)
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft pulley (A).
Tightening torque

11T:

127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 Ib-ft)

12T: [46.1 ~ 52.0 N.m (4.7 ~ 5.3 kgf.m, 34.0 ~ 38.3 Ib-ft)] + [38°~ 42°]

Fig 10: Locating Crankshaft Pulley
Courtesy of HYUNDAI MOTOR AMERICA

Fig 11: Crankshaft Damper Pulley Bolts & Nuts Specification Chart
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 12: Holding Ring Gear Using SST (09231-2B100)
  Courtesy of HYUNDAI MOTOR AMERICA
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the bracket (A).
  
  Fig 13: Locating Bracket And Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 14: Locating Dust Cover And Transaxle Mounting Bolt
  Courtesy of HYUNDAI MOTOR AMERICA
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. Adjust the angle of the links (D), and fasten the bolt 70mm (2.7559in) in the original mounted hole.
  
  Fig 15: Adjusting Ring Gear, Holder, Holder Nuts And Links
  Courtesy of HYUNDAI MOTOR AMERICA
5. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 16: Tightening Bolts Or Nuts Of Holder And Links
  Courtesy of HYUNDAI MOTOR AMERICA
NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 17: Locating Pulley Timing Mark
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Install the water pump (A) with a gasket.
Tightening torque :

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

Fig 18: Locating Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque

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

B: 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Fig 19: Locating Water Pump Pulley & Drive Belt Idler With Bolts
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Tighten the bolts diagonally.
Install the engine support bracket (A).
Tightening torque :

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
Install the alternator bracket (B).
Tightening torque :

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

Fig 20: Installing Alternator Bracket And Engine Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Install the engine mounting support bracket (B) and then connect the ground line (A).
Tightening torque

Ground line bolt:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

Nut (C):

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

Bolt (D) and nuts (E):

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

Fig 21: Locating Engine Mounting Support Bracket, Ground Line Bolts & Nuts
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator (A).
Tightening torque

M8 bolt:

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

M10 bolt:

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

Fig 22: Locating Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt (A).

Fig 23: Engine Drive Belt Routing Diagram
Courtesy of HYUNDAI MOTOR AMERICA
Adjust tension by tightening the alternator tension adjust bolt (A).
(Refer to ALTERNATOR )

Tension

New belt:

882.6 ~ 980.7 N (90 ~ 100 kg, 198.4 ~ 220.5 lb)

Used belt:

637.4 ~ 735.5 N (65 ~ 75 kg, 143.3 ~ 165.3 lb)

Fig 24: Adjusting Alternator Tension Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
After applying the liquid gasket, Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.
Width: 2.0 ~ 2.5 mm (0.0787 ~ 0.0984 in.)

Fig 25: Liquid Gasket Applying Area On Cylinder Head Cover
Courtesy of HYUNDAI MOTOR AMERICA
Install the OCV (Oil Control Valve) adapter (A).
Tightening torque :

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

Fig 26: Locating Oil Control Valve Adapter With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- Keep the OCV adapter clean.
- Make sure the O-rings on the front bearing cap are installed.
Install the cylinder head cover (A) with a new gasket (B).

Fig 27: Locating Cylinder Head Cover And Gasket
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Do not reuse the disassembled gasket.
Tighten the cylinder head cover bolts with the order and steps.
Tightening torque

1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 28: Cylinder Head Cover Bolts Tightening Sequence
Courtesy of HYUNDAI MOTOR AMERICA
Install the exhaust OCV (Oil Control Valve) (A).
Tightening torque :

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

Fig 29: Locating Exhaust Oil Control Valve With Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Install the ignition coils (A).
Tightening torque:

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

Fig 30: Locating Ignition Coils With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the high pressure fuel pump (A) and the roller tappet (B).
(Refer to HIGH PRESSURE FUEL PUMP )

Tightening torque :

12.7 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.8 lb-ft)

Fig 31: Locating High Pressure Fuel Pump And Roller Tappet With Bolts
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

NOTE: Do not use already used bolt again.

NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5turns) after tightening them with hand-screwed torque.

CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

CAUTION: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

Fig 32: Applying Engine Oil To O-Ring, Roller Tappet And Protrusion
Courtesy of HYUNDAI MOTOR AMERICA
Install the high pressure pipe (A).
(Refer to HIGH PRESSURE FUEL PUMP )

Tightening torque :

25.5 ~ 31.4 N.m (2.6 ~ 3.2 kgf.m, 18.8 ~ 23.1 lb-ft)

Fig 33: Locating High Pressure Pipe
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Do not reuse the high pressure pipe.
Install the vacuum pipe assembly (A).
Tightening torque :

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

Fig 34: Locating Vacuum Pipe Assembly With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Connect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 35: Locating Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of HYUNDAI MOTOR AMERICA
Connect the oxygen sensor connectors (A) and the condenser connector (B).

Fig 36: Locating Oxygen Sensor Connectors And Condenser Connector
Courtesy of HYUNDAI MOTOR AMERICA
Connect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).

Fig 37: Locating Fuel Pressure Control Valve, Intake Camshaft Position Sensor & Exhaust Camshaft Position Sensor Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Connect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).

Fig 38: Locating Ignition Coil, Injector Extension, Variable Intake System & Purge Control Solenoid Valve Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Connect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).

Fig 39: Locating Intake And Exhaust Oil Control Valve Connector
Courtesy of HYUNDAI MOTOR AMERICA
Connect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).
Tightening torque :

9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

Fig 40: Locating A/C Compressor Switch, Alternator Connectors And Alternator B Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Install the under covers (A).
Tightening torque :

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

Fig 41: Locating Under Covers With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (D) and then connect the air intake hose (C).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
2. Connect the breather hose (B).
3. Install the air duct (A).
Fig 42: Locating Air Cleaner Assembly, Air Intake Hose, Breather Hose & Air Duct
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
- Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
Fig 43: Air Intake Hose Installation Position
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Connect the battery negative terminal (A).
Tightening torque

Without battery sensor:

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

With battery sensor:

4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)

Fig 44: Locating Battery Negative Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Install the engine cover.
CAUTION: Make sure the engine cover is installed before driving.