Repair Procedures: Installation: [Rear]

Fig 1: Identifying Hole On Timing Chain Lower Cover (Rear)

Courtesy of HYUNDAI MOTOR CO.

5. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.

6. 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.
7. Install the camshaft assembly. (Refer to CYLINDER HEAD ASSEMBLY in this group)
8. Remove the SST from the timing chain guide and the timing chain tensioner arm.
9. Install the timing chain to the CVVT sprocket. (Refer to CYLINDER HEAD ASSEMBLY in this group)

Fig 2: Identifying Timing Chain On CVVT Sprocket
Courtesy of HYUNDAI MOTOR CO.

Fig 3: Identifying Timing Marks Of Sprockets (1 Of 3)
Courtesy of HYUNDAI MOTOR CO.

Fig 4: Identifying Timing Marks Of Sprockets (2 Of 3)
Courtesy of HYUNDAI MOTOR CO.

Fig 5: Identifying Timing Marks Of Sprockets (3 Of 3)
Courtesy of HYUNDAI MOTOR CO.

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket → Timing chain guide → Exhaust CVVT sprocket → Intake CVVT sprocket. (LH Bank)
Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket. (RH Bank)
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain during installation.
10. 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)
11. 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.
12. Install the O-ring (A) to the water temperature control assembly.

Fig 6: Identifying O-Ring Of Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR CO.
13. 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 7: Identifying Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR CO.
14. Install the water pump (A).
Tightening torque:

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

Fig 8: Identifying Water Pump
Courtesy of HYUNDAI MOTOR CO.
15. Using SST(09231-2J300, 09231-H1100), Install the front oil seal (A).

Fig 9: Installing Front Oil Seal Using SST
Courtesy of HYUNDAI MOTOR CO.
16. Install the crankshaft pulley (A).
Tightening torque:

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

Fig 10: Identifying Crankshaft Pulley
Courtesy of HYUNDAI MOTOR CO.

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

Fig 11: Installing Crankshaft Pulley Bolt Using SST (Ring Gear Stopper, 09231-2B100)
Courtesy of HYUNDAI MOTOR CO.
17. 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 equivalent 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 12: Identifying Sealant Applying Area Of Upper Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  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 13: Identifying Upper Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 14: Upper Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR CO.
18. 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 LT5900H or equivalent 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 15: Identifying Sealant Applying Area Of Lower Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  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 16: Identifying Lower Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 17: Lower Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR CO.
19. Install the oil filter & cooler assembly (B).
Tightening torque:

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

Fig 18: Identifying Oil Filter & Cooler Assembly
Courtesy of HYUNDAI MOTOR CO.
20. Install the water pump pulley (A).
Tightening torque:

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

NOTE: Tighten each bolt gradually in a criss-cross pattern until the final tightening torque has been reached.

Fig 19: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR CO.
21. Install the drive belt tensioner (A).
Tightening torque:

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

Fig 20: Identifying Drive Belt Tensioner
Courtesy of HYUNDAI MOTOR CO.
22. Install the drive belt idler (A).
Tightening torque:

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

Fig 21: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR CO.
23. Install the air conditioner compressor (A). (Refer to INSTALLATION )

Fig 22: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR CO.
24. 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 23: Identifying Alternator Bracket
Courtesy of HYUNDAI MOTOR CO.
25. Install the alternator (A). (Refer to INSTALL )
Tightening torque:

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

Fig 24: Identifying Alternator
Courtesy of HYUNDAI MOTOR CO.
26. Install the removed parts. (Refer to CYLINDER HEAD ASSEMBLY installation procedure in this group)