Timing Belt: Installation

The method of installing timing belt and auto tensioner.

1. Install idler pulley to engine support lower bracket.
   Fig 1: Identifying Idler Pulley On Engine Support Lower Bracket

   Courtesy of HYUNDAI MOTOR CO.
2. Install tensioner arm, shaft and plane washer to cylinder block.

   Tightening torque  : 35 ~55 Nm (350 ~ 550 kg.cm)

   Fig 2: Installing Tensioner Arm

   Courtesy of HYUNDAI MOTOR CO.
3. Install crankshaft sprocket and align the timing mark.
   Fig 3: Installing Crankshaft Sprocket

   Courtesy of HYUNDAI MOTOR CO.
   CAUTION: Be careful not to bend crankshaft sensing blade.
   Fig 4: Identifying Crankshaft Sprocket, Sensing Blade & Spacer

   Courtesy of HYUNDAI MOTOR CO.
4. Install camshaft sprocket and adjust initial installation state as illustration.
   Fig 5: Camshaft Sprocket Initial Installation

   Courtesy of HYUNDAI MOTOR CO.
5. Install auto tensioner to oil pump case.
   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 6: Identifying Auto Tensioner

      Courtesy of HYUNDAI MOTOR CO.
      Fig 7: Aligning Set Hole

      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.
6. Align the timing marks of each sprocket and install the timing belt in this order.

   Crankshaft sprocket, Idler pulley, Exhaust camshaft sprocket (LH), Intake camshaft sprocket (RH), Exhaust camshaft sprocket (RH) and then Tensioner pulley

   Fig 8: Aligning Timing Marks

   Courtesy of HYUNDAI MOTOR CO.
   NOTE:

   • In this step, No. 1 is in TDC (Compression stroke)
   • Do not insert fingers.
7. After installing the timing belt, reconfirm the timing mark.
8. Timing belt tension adjustment
   1. Setting tension (under Non-operation of auto tensioner : set pin installed)
      1. After turning the crankshaft 1/4 revolution counter clockwise, turn it clockwise to fit it in the position counter clockwise, turn it clockwise to fit it in the position of No. 1 TDC. Release the center bolt, and apply the tension to the belt using tensioner pulley socket and torque wrench as shown illustration and then tighten the center bolt by specified torque.
         Fig 9: Applying Tension To Belt

         Courtesy of HYUNDAI MOTOR CO.

         Tension torque : 5Nm (50kg.cm, 3.71 lb.ft)

         NOTE: Be careful not to turn the tensioner pulley with the center bolt when tightening the center bolt.

         Tightening torque 

         Tensioner bolt :

         43 ~ 55Nm (430 ~ 550kg.cm, 31 ~ 39lb.ft)

      2. Pull out the set pin of auto tensioner
   2. Tension checking (under operation of auto tensioner : set pin removed)
      1. Rotate the crankshaft 2 rotation clockwise and measure the projected load of auto tensioner in the TDC (#1 compression stroke) after 5 minutes.
      2. Check the projected length is 3.8 ~ 4.5 mm.
      3. Check again if the timing marks of each sprocket is with in specified position.
9. Install the engine support bracket.
10. Install the timing belt cover.
11. Install the alternator and drive belt.
12. Install the engine mounting bracket.
13. Install the side cover.
14. Install the wheel of passenger side.