Timing Belt: Installation

Install the crankshaft sprocket "B" into the crankshaft.
CAUTION: Pay attention to the direction of the flange. if it is installed in the wrong direction, a broken belt could result.

Fig 1: Identifying Crankshaft Sprocket "B"
Courtesy of HYUNDAI MOTOR CO.
Apply engine oil to the outer surface of the spacer lightly and then install the spacer to the right counter balance shaft. Be sure to install in the direction shown in the illustration.
Install the counter balance shaft sprocket onto the right counter balance shaft and then tighten its flange bolt by hand tightly.

Fig 2: Installing Counter Balance Shaft
Courtesy of HYUNDAI MOTOR CO.
Align the timing mark on each sprocket with the corresponding timing mark on the front case.

Fig 3: Identifying Timing Marks
Courtesy of HYUNDAI MOTOR CO.
When the timing belt "B" is installed, make certain that its tension side has no slack.
Install the tensioner "B" so the center of the pulley is located on the left side of the mounting bolt and in the pulley flange faces the front of the engine.

Align the timing mark on the right counter balance shaft sprocket with the timing mark on the front case.

Fig 4: Installing Timing Belt "B"
Courtesy of HYUNDAI MOTOR CO.
Lift the tensioner "B" to tighten the timing belt "B" so that its tension side is pulled tight. In this condition, tighten the bolt to secure tensioner "B". As the bolt is tightened, be careful to prevent the shaft from turning. If the shaft is turned, the belt will be tightened excessively.

Fig 5: Tightening Tensioner "B"
Courtesy of HYUNDAI MOTOR CO.
Check to ensure that the timing marks are in alignment.
Verify the tension of the timing belt.
Method 1 : Verify that, when the center of the span on the tension side is depressed with an index finger in the direction of arrow, the deflection of the belt is within specification.

Belt deflection : 5 ~ 7 mm (0.20 ~ 0.28 in)

Method 2 : Measure the tension of the timing belt by using a tension gauge.

Fig 6: Belt Tension Specification Table
Courtesy of HYUNDAI MOTOR CO.

Fig 7: View Of Timing Belt & Alignment Marks
Courtesy of HYUNDAI MOTOR CO.
Install the flange and crankshaft sprocket onto the crankshaft. Be sure to install the as shown in the illustration.
CAUTION: Pay attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.

Fig 8: Installing Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Install the special washer and sprocket bolt to the crankshaft and then tighten the sprocket bolt.
Tightening torque

Crankshaft sprocket bolt :

160 ~ 170 Nm (1600 ~ 1700 kg.cm, 116 ~ 123 lb.ft)
Insert a screwdriver through the plug hole in the left side of the cylinder block to keep the shaft in position.

Fig 9: Identifying Screw Driver In Plug Hold
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump sprocket and tighten the nut to the specified torque.

Fig 10: Tightening Oil Pump Sprocket
Courtesy of HYUNDAI MOTOR CO.

Tightening torque

Oil pump sprocket

50 ~ 60 Nm (500 ~ 600 kg.cm, 36 ~ 43 lb.ft)
Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque

Camshaft sprocket bolt :

80 ~ 100 Nm (800 ~ 1000 kg.cm, 58 ~ 72 lb.ft)
Install the auto tensioner.
CAUTION: Leave the set pin installed in the auto tensioner.

Fig 11: Installing Auto Tensioner
Courtesy of HYUNDAI MOTOR CO.
NOTE:
If the auto tensioner rod is in its fully extended position, reset it as follows.
1. Clamp it in a vise equipped with soft jaws, in a level position. Use a plain washer if there is a plug at the bottom of the auto tensioner.
2. Compress the rod slowly with the vise until the set hole in the rod is aligned with set hole in the cylinder.
  
  Fig 12: Compressing Rod In A Vise
  Courtesy of HYUNDAI MOTOR CO.
3. Insert a set pin through the auto tensioner body and rod.
CAUTION: Leave the set pin installed in the auto tensioner.
Install the tensioner pulley onto the tensioner arm.
Tightening torque

Tensioner pulley

43 ~ 55 N.m (430 ~ 550 kg.cm, 31 ~ 40 lb.ft)

Fig 13: Identifying Tensioner Pulley
Courtesy of HYUNDAI MOTOR CO.
Rotate the camshaft sprockets so that the dowel pin of the camshaft sprocket is at the upper side. Set the timing mark of sprocket correctly.
NOTE:
1. Before installing the timing belt, if the timing mark of the cam sprocket doesn't coincide with that of the rocker cover, do not rotate the cam sprocket more than 2 teeth of the sprocket in any direction. Rotating the sprocket more than 2 teeth may make the valve and piston touch each other.
2. If it is necessary to rotate the cam sprocket more than 2 teeth, rotate the crank sprocket counter clock wise first based on the timing mark.
  After the cam sprocket is properly timed return the crankshaft to TDC.
  
  Fig 14: Identifying Dowel Pin & Camshaft Timing Marks
  Courtesy of HYUNDAI MOTOR CO.
3. When exhaust and intake camshaft sprocket is used and install it after checking I.D mark depending on the engine debasement.
Fig 15: Identifying Camshaft Sprocket I.D. Mark
Courtesy of HYUNDAI MOTOR CO.
Align the timing mark on each sprocket with the corresponding timing mark and install the belt as the following order.
Crankshaft sprocket - Oil pump sprocket - Idler pulley - Exhaust camshaft sprocket - Intake camshaft sprocket Tensioner pulley

Fig 16: Identifying Timing Belt & Pulleys
Courtesy of HYUNDAI MOTOR CO.
NOTE:
1. Be sure that the piston of No. 1 cylinder is located in TDC position (Compression stroke).
2. When aligning the timing mark on oil pump sprocket, remove the left plug of cylinder block, and then check that the count balance shaft is in the specified position by inserting the screwdriver (Diameter : 8 mm, inserting length : 60 mm or more)
  
  Fig 17: Checking Counter Balance Shaft Position
  Courtesy of HYUNDAI MOTOR CO.
3. After checking the timing mark, install the left plug of cylinder block.
  Tightening torque : 2.7 - 3.4 kgf.m
  
  (Apply the liquid gasket : THREE BOND NO. 1212B or equivalent)
Pull out the set pin.
Rotate the crankshaft two turns clockwise and leave it for about 5 minutes. Then, measure the auto tensioner protrusion "A" (Distance between the tensioner arm and auto tensioner body) to ensure that it is within the specification.
Standard value : 5.5-9 mm (0.22 - 0.35 in)

Fig 18: Measuring Auto Tensioner Protrusion
Courtesy of HYUNDAI MOTOR CO.
Install the timing belt lower cover and the timing belt upper cover.

Fig 19: Identifying Timing Belt Cover Bolts

Courtesy of HYUNDAI MOTOR CO.