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Home › Hyundai › 2007 › Azera GLS › Repair and Diagnosis › Engine Mechanical › Timing Belt › Engine (G6DB/G6DA-GSL 3.3/3.8) › Timing System › Timing Chain › Repair procedures › Removal

Repair procedures: Removal

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
  • Mark all wiring and hoses to avoid misconnection.
  • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
  1. Disconnect the negative terminal from the battery.
  2. Remove the engine cover.
  3. Remove the air duct.
    Fig 1: Identifying Air Duct
    G07759076
  4. Remove the intake air hose and air cleaner assembly.
    1. Disconnect the AFS connector (A).
    2. Disconnect the breather hose (B) from air cleaner hose.
    3. Disconnect the ECM connector.
    4. Remove the intake air hose (C) and air cleaner (D).
      Fig 2: Identifying AFS Connector, Breather Hose And Intake Air Hose
      G07759077
  5. Remove the RH front wheel.
  6. Remove the under cover (A).
    Fig 3: Identifying Under Cover
    G07759078
  7. Remove the side cover (A).
    Fig 4: Identifying Side Cover
    G07759079
  8. Drain the engine coolant.

    Remove the radiator cap to speed draining.

  9. Remove the upper radiator hose (A).
    Fig 5: Identifying Upper Radiator Hose
    G07759080
  10. Drain the engine oil.
  11. Remove the lower oil pan (A).
    Fig 6: Inserting SST Between Oil Pan And Ladder Frame
    G07759081
    NOTE:
    • Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
    • After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
    • Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
    • Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
  12. Install the jack to the upper oil pan.
    Fig 7: Installing Jack To Upper Oil Pan
    G07759082
  13. Just loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B).
    Fig 8: Identifying Transaxle Mounting Bolts
    G07759083
  14. Remove the engine coolant reservoir tank (A).
  15. Remove the engine mounting bracket (B).
    Fig 9: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
    G07759084
  16. Loosen the A/C pipe bracket mounting bolt (A).
    Fig 10: Identifying A/C Pipe Bracket Mounting Bolt
    G07759085
  17. Remove the no.1 engine mounting (A) through the lower position of A/C pipe line.
    Fig 11: Identifying No.1 Engine Mounting
    G07759086
  18. Remove the surge tank and engine wiring.
    1. Disconnect the RH oxygen sensor connector (A).

      [3.3L] 

      Fig 12: Identifying RH Oxygen Sensor Connector
      G07759087
    2. Disconnect the RH oxygen sensor connector (A) and VIS solenoid valve connector (B).
      Fig 13: Identifying RH Oxygen Sensor Connector And VIS Solenoid Valve Connector
      G07759088
    3. Disconnect the power steering oil pressure sensor connector (A).
      Fig 14: Identifying Power Steering Oil Pressure Sensor Connector
      G07759089
    4. Disconnect the RH injector connector (A) and the ignition coil connector (B).

      [3.3L] 

      Fig 15: Identifying RH Injector Connector And Ignition Coil Connector
      G07759090
      Fig 16: Identifying RH Injector Connector And Ignition Coil Connector (3.8L)
      G07759091
    5. Disconnect the OCV connector (A) and knock sensor connector(B).
    6. Disconnect the LH front oxygen sensor connector (C), alternator connector (D) and air compressor connector (E).
      Fig 17: Identifying OCV Connector And Knock Sensor Connector, LH Front Oxygen Sensor Connector, Alternator Connector And Air Compressor Connector
      G07759092
    7. Disconnect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D), and remove the wiring harness protector (E).
      Fig 18: Identifying Ignition Coil Connector, Injector Connector, Condenser Connector And Ground
      G07759093
    8. Disconnect the LH CMPS (A) and oil pressure switch connector (B).
      Fig 19: Identifying LH CMPS And Oil Pressure Switch Connector
      G07759094
    9. Disconnect the ETC connector (A) and the knock sensor connector (B).
      Fig 20: Identifying ETC Connector And Knock Sensor Connector
      G07759095
    10. Disconnect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose (C).

      [3.3L] 

      Fig 21: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.3L)
      G07759096
      Fig 22: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.8L)
      G07759097
    11. Remove the ETC bracket (A).
    12. Disconnect the water hoses (B) from the ETC.
    13. Disconnect the PCV(C) hose.
      Fig 23: Identifying ETC Bracket, Water Hoses And PCV Hose
      G07759098
    14. Disconnect the brake vacuum hose.
    15. Remove the surge tank stay (A).

      [3.3L] 

      Fig 24: Identifying Surge Tank Stay (3.3L)
      G07759099
      Fig 25: Identifying Surge Tank Stay (3.8L)
      G07759100
    16. Remove the connector bracket (A) from the surge tank.
      Fig 26: Identifying Connector Bracket With Mounting Screws
      G07759101
    17. Remove the surge tank (A).

      [3.3L] 

      Fig 27: Identifying Surge Tank With Mounting Screw (3.3L)
      G07759102
      Fig 28: Identifying Surge Tank With Mounting Screw (3.8L)
      G07759103
      NOTE:
      • Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
  19. Remove the cylinder head cover.
    1. Remove the connector bracket (A) from the LH cylinder head cover.
      Fig 29: Identifying Cylinder Head Cover Connector Bracket
      G07759104
    2. Disconnect the RH ignition coil connector (A), the condenser connector (B) and remove the wiring bracket (C).
      Fig 30: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
      G07759105
    3. Remove the LH, RH ignition coil.
    4. Remove the LH, RH cylinder head cover (A).
      Fig 31: Identifying LH, RH Cylinder Head Cover
      G07759106
      NOTE:
      • Cover the upside of engine head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
  20. Set No. 1 cylinder to TDC/compression.
    1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.
      NOTE: Do not rotate engine counterclockwise.
      Fig 32: Identifying Crankshaft Pulley
      G07759107
    2. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.

      If not, turn the crankshaft one revolution (360°).

      Fig 33: Identifying Camshaft Timing Sprockets Mark
      G07759108
      NOTE: Do not rotate engine counterclockwise.
  21. Remove the drive belt (A).
    Fig 34: Identifying Drive Belt
    G07759109
  22. Remove the crankshaft damper pulley (A).
    Fig 35: Identifying Crankshaft Damper Pulley
    G07759110
    NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
    • Install the SST (09231-3C300) to hold the ring gear after removing the starter.
      Fig 36: Holding Ring Gear Using SST (09231-3C300)
      G07759111
    • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
    1. Remove the front muffler. (Refer to Intake And Exhaust system)
    2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
      Fig 37: Identifying Dust Cover And Transaxle Mounting Bolts
      G07759112
    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.
      Fig 38: Identifying Holder Nuts, Front Plate Of Holder And Ring Gear
      G07759113
    5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
      Fig 39: Installing SST (09231-3D100) Using Mounting Bolts
      G07759114
  23. Lift up the engine assembly by using the jack.
  24. Remove the power steering pump (A).
    Fig 40: Identifying Power Steering Pump
    G07759115
  25. Remove the air conditioner compressor (A).
    Fig 41: Identifying Air Conditioner Compressor
    G07759116
  26. Remove the alternator (A).
    Fig 42: Identifying Alternator
    G07759117
  27. Remove the drive belt idler (A).
    Fig 43: Identifying Drive Belt Idler
    G07759118
  28. Remove the drive belt auto tensioner (A).
    Fig 44: Identifying Drive Belt Auto Tensioner
    G07759119
  29. Remove water pump pulley (A).
    Fig 45: Identifying Water Pump Pulley
    G07759120
  30. Remove the timing chain cover (A).
    Fig 46: Identifying Timing Chain Cover
    G07759121
    CAUTION:
    • Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
    NOTE:
    • Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
      Fig 47: Identifying Sprocket RH/LH Timing Chain Mark
      G07759122
      Fig 48: Identifying Timing Chain Mark
      G07759123
      Fig 49: Identifying Sprocket RH/LH Timing Chain Mark
      G07759124
      Fig 50: Identifying Timing Chain
      G07759125
  31. Install a set pin after compressing the RH timing chain tensioner.
    Fig 51: Compressing RH Timing Chain Tensioner
    G07759126
  32. Remove the RH cam-to-cam guide (A).
    Fig 52: Identifying Cam-To-Cam Guide
    G07759127
  33. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
    Fig 53: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
    G07759128
  34. Remove the RH timing chain.
  35. Remove the RH timing chain guide (A).
    Fig 54: Identifying RH Timing Chain Guide
    G07759129
  36. Remove the oil pump chain cover (A).
    Fig 55: Identifying Oil Pump Chain Cover
    G07759130
  37. Remove the oil pump chain tensioner assembly (A).
    Fig 56: Identifying Oil Pump Chain Tensioner Assembly
    G07759131
  38. Remove the oil pump chain guide (A).
    Fig 57: Identifying Oil Pump Chain Guide
    G07759132
  39. Remove the oil pump chain sprocket (A) and oil pump chain (B).
    Fig 58: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
    G07759133
  40. Remove the crankshaft sprocket (A) (O/P & RH camshaft drive).
    Fig 59: Identifying Crankshaft Sprocket
    G07759134
  41. Install a set pin after compressing the LH timing chain tensioner.
    Fig 60: Compressing RH Timing Chain Tensioner
    G07759135
  42. Remove the LH cam-to-cam guide (A).
    Fig 61: Identifying Cam-To-Cam Guide
    G07759136
  43. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
    Fig 62: Identifying LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
    G07759137
  44. Remove the LH timing chain.
  45. Remove the LH timing chain guide (A).
    Fig 63: Identifying LH Timing Chain Guide
    G07759138
  46. Remove the crankshaft sprocket (A) (LH camshaft drive).
    Fig 64: Identifying Crankshaft Sprocket (LH Camshaft Drive)
    G07759139
  47. Remove the tensioner adapter assembly (A).
    Fig 65: Identifying Tensioner Adapter Assembly
    G07759140
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