Repair procedures: Installation

WARNING: This page is about a different variant/trim than selected.

The key (A) of crankshaft should be aligned with the timing mark (B) of cylinder block. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 1: Identifying Crankshaft Key And Cylinder Block Timing Mark
Courtesy of HYUNDAI MOTOR AMERICA
Install the tensioner adapter assembly (A).

Fig 2: Identifying Tensioner Adapter Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft LH timing chain sprocket (A).

Fig 3: Identifying Crankshaft LH Timing Chain Sprocket
Courtesy of HYUNDAI MOTOR AMERICA
Install the LH timing chain (A).

Fig 4: Identifying LH Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

Fig 5: Identifying Timing Mark On LH Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket → Intake camshaft sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
Install the LH timing chain guide (A).
Tightening torque:

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

Fig 6: Identifying LH Timing Chain Guide
Courtesy of HYUNDAI MOTOR AMERICA
Install the LH timing chain tensioner arm (B) and LH timing chain auto tensioner (A).
Tightening torque
1. 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
  
  Fig 7: Identifying LH Timing Chain Tensioner Arm And LH Timing Chain Auto Tensioner
  Courtesy of HYUNDAI MOTOR AMERICA
Install the LH timing chain cam to cam guide (A).
Tightening torque:

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

Fig 8: Identifying LH Timing Chain Cam Guide
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tensioner stopper pin (A).

Fig 9: Identifying Tensioner Stopper Pin
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft oil pumpchain sprocket (A).

Fig 10: Identifying Crankshaft Oil Pump Chain Sprocket
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil pump chain sprocket (A) with oil pump chain (B).
Tightening torque:

18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

Fig 11: Identifying Oil Pump Chain And Sprocket
Courtesy of HYUNDAI MOTOR AMERICA
Install the RH timing chain (A).

Fig 12: Identifying RH Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

Fig 13: Identifying Timing Mark On RH Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket →Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
Install the RH timing chain guide (A).
Tightening torque:
1. 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
  
  Fig 14: Identifying RH Timing Chain Guide
  Courtesy of HYUNDAI MOTOR AMERICA
Install the RH timing chain tensioner arm (B) and RH timing chain auto tensioner (A).
Tightening torque
1. 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
  
  Fig 15: Identifying RH Timing Chain Tensioner Arm And RH Timing Chain Auto Tensioner
  Courtesy of HYUNDAI MOTOR AMERICA
Install the RH timing cam to cam guide (A).
Tightening torque:

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

Fig 16: Identifying RH Timing Cam Guide
Courtesy of HYUNDAI MOTOR AMERICA
Remove the tensioner stopper pin (A).

Fig 17: Identifying Tensioner Stopper Pin
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil pump chain tensioner assembly (A).
Tightening torque:

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

Fig 18: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: The hook of tensioner must be around the guide.
Install the oil pump chain cover (A).
Tightening torque:

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

Fig 19: Identifying Oil Pump Chain Cover
Courtesy of HYUNDAI MOTOR AMERICA
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.
Install the timing chain cover.
1. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
2. Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between cylinder head and cylinder block.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Bead width: 2.5mm (0.1in.)
  
  Fig 20: Identifying Timing Mark On Timing Chain
  Courtesy of HYUNDAI MOTOR AMERICA
3. After applying liquid sealant TB1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied.
  Sealant should be applied without discontinuity.
  
  Fig 21: Identifying Liquid Sealant Applying Area On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - Fill the T-joint area (6EA*) with sealant.
  - Apply sealant all around the dowel pin hole (2EA).
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 22: Identifying Timing Chain Cover Gasket
  Courtesy of HYUNDAI MOTOR AMERICA
  
  NOTE: During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.
5. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
  Tightening torque
  1. (16EA):
    18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
  2. (2EA):
    24.5 ~ 26.5N.m (2.5 ~ 2.7kgf.m, 18.1 ~ 19.5lb-ft)
  3. (2EA):
    58.8 ~ 68.6N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
  4. (3EA):
    9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
    
    Fig 23: Identifying Timing Chain Cover Mounting Bolts
    Courtesy of HYUNDAI MOTOR AMERICA
6. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install the water pump.
Install the new gaskets (B) and then install the water pump (A).

Fig 24: Identifying Water Pump Gaskets
Courtesy of HYUNDAI MOTOR AMERICA

Fig 25: Identifying Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Clean the contact face before assemble.
- Always use a new seal bolt (Bolt C) and the gaskets.
Tightening torque
1. (3EA):
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. (1EA):
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
3. (1EA):
  19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
4. (1EA):
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
5. (1EA):
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. (1EA):
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
7. (4EA):
  19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)
  
  Fig 26: Identifying Water Pump Seal Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 27: Installing Timing Chain Cover Oil Seal Using SST (09231-3C100)
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft pulley (A).
Tightening torque:

284.4 ~304.0N.m (29.0~31.0kgf.m, 209.8~224.2lb-ft)

Fig 28: Identifying Crankshaft Pulley
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Use the SST (09231-3M100) to install the crankshaft pulley bolt.
Fig 29: Installing Crankshaft Pulley Bolt Using SST (09231-3M100)
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt auto tensioner (A).
Tightening torque

Bolt (B):

81.4 ~ 85.3N.m (8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft)

Bolt (C):

17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)

Fig 30: Identifying Drive Belt Auto Tensioner And Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt idler (A).
Tightening torque:

53.9 ~ 57.9N.m (5.5 ~ 5.9kgf.m, 39.8 ~ 42.7lb-ft)

Fig 31: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A).
Tightening torque:

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

Fig 32: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil filter body (A).
Tightening torque:

19.6 ~ 21.6N.m (2.0 ~ 2.2kgf.m, 14.5 ~ 15.9lb-ft)

Fig 33: Identifying Oil Filter Body
Courtesy of HYUNDAI MOTOR AMERICA
Install the air conditioner compressor (A). (Refer to COMPRESSOR )

Fig 34: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator (A). (Refer to ALTERNATOR )
Tightening torque:

26.5 ~ 33.3N.m (2.7 ~ 3.4kgf.m, 19.5 ~ 24.6lb-ft)

Fig 35: Identifying Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Rotate the auto tensioner counterclockwise. With the tensioner turned, install the drive belt (A).

Fig 36: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR AMERICA
Install the lower oil pan (A).
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB 1217H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied.
  Bead width: 2.5mm (0.1in.)
  
  Fig 37: Identifying Liquid Sealant Applying Area On Lower Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  CAUTION:
  - Clean the sealing face before assembling two parts.
  - Remove harmful foreign matters on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not be protruded 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 oil pan (A).
  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 38: Identifying Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
Install the LH/RH cylinder head cover (A).
CAUTION:
- Install the cylinder head cover under the exhaust OCV cup is removed.
- To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant (TB1217H), it should be assembled within 5 minutes.
  Bead width: 2.5mm (0.1in.)
  
  Fig 39: Identifying Sealant Applying Area Between Timing Chain Cover And Cylinder Head
  Courtesy of HYUNDAI MOTOR AMERICA
3. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
4. Install the cylinder head cover bolts as following method.
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  CAUTION: Do not reuse cylinder head cover gasket.
  
  Fig 40: Identifying Tightening Sequence Of Cylinder Head Cover Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
5. Install the exhaust OCV cap.
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the RH ignition coils (A) and then connect the connectors.
Tightening torque:

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

Fig 41: Identifying RH Ignition Coils
Courtesy of HYUNDAI MOTOR AMERICA
Install the LH ignition coils (A) and then connect the connectors.
Install the roller tappet (C) and the fuel pump (B).

Tightening torque

Ignition coil bolts:

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

Fuel pump bolts:

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

Fig 42: Identifying LH Ignition Coils, Roller Tappet And Fuel Pump
Courtesy of HYUNDAI MOTOR AMERICA
Install high pressure fuel pipe (A).
Tightening torque:

26.5 ~ 32.4N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9lb-ft)

Fig 43: Identifying High Pressure Fuel Pipe
Courtesy of HYUNDAI MOTOR AMERICA
Install the intake manifold (B) and then connect the water hose (C) and the pipe (A).

Fig 44: Identifying Intake Manifold, Pipe And Water Hose
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Tighten the intake manifold bolts, in several passes as below.
a~h: 1st step order
1~8: 2nd step order

Tightening torque

Step 1:

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

Step 2:

26.5 ~ 31.4N.m (2.7 ~ 3.2kgf.m, 19.5 ~ 23.1 lb-ft)

Step 3: Repeat 2nd step twice or more

Fig 45: Identifying Tightening Sequence Of Intake Manifold Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the fuel tube bracket bolt (A).
Tightening torque:

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

Fig 46: Identifying Fuel Tube Bracket Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Install the breather pipe & hose (A).
Tightening torque:

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

Fig 47: Identifying Breather Pipe & Hose
Courtesy of HYUNDAI MOTOR AMERICA
Install the surge tank assembly (A).
Tightening torque:

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

Fig 48: Identifying Surge Tank Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Connect the engine wiring harness connectors and hoses.
1. RH ignition coil connector (A)
2. RH knock sensor connector (B)
  
  Fig 49: Identifying RH Ignition Coil Connector And RH Knock Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
3. RH exhaust oil control valve (OCV) connector (A)
4. RH injector connector (B)
5. VIS solenoid valve connector (C)
  
  Fig 50: Identifying RH Exhaust OCV Connector, RH Injector Connector And VIS Solenoid Valve Connector
  Courtesy of HYUNDAI MOTOR AMERICA
6. LH exhaust oil control valve (OCV) connector (A)
7. LH/RH intake oil control valve (OCV) connector (B)
8. Oil pressure switch connector (C)
9. LH Injector connector (D)
10. Ignition coil condenser connector (E)
11. LH knock sensor connector (F)
  
  Fig 51: Identifying OCV Connector, Oil Pressure Switch Connector, Injector Connector, Ignition Coil Condenser Connector And Knock Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
12. ETC connector (A), PCV hose (B)
13. RH exhaust camshaft position sensor (CMPS) connector (C)
14. Water temperature sensor (D)
15. Ignition coil condenser connector (E)
16. RH front oxygen sensor connector (F)
  
  Fig 52: Identifying ETC Connector, CMPS Connector, Water Temperature Sensor, Ignition Coil Condenser Connector, Front Oxygen Sensor Connector And PCV Hose
  Courtesy of HYUNDAI MOTOR AMERICA
17. Fuel pump connector (A)
18. LH ignition coil connector (B)
19. LH exhaust camshaft position sensor (CMPS) connector (C)
20. LH front oxygen sensor connector (D)
  
  Fig 53: Identifying Fuel Pump Connector, Ignition Coil Connector, CMPS Connector And Front Oxygen Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
21. PCSV connector (A)
22. LH intake camshaft position sensor (CMPS) connector (B)
23. MAP sensor connector (C)
24. Oil temperature sensor connector (D)
25. RH intake camshaft position sensor (CMPS) connector (E)
  
  Fig 54: Identifying CMPS Connector, PCSV Connector, MAP Sensor Connector And Oil Temperature Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
Install the fuel hose (A), PCSV hose (B) and the intensifier hose (C).

Fig 55: Identifying Fuel Hose, PCSV Hose And Intensifier Hose
Courtesy of HYUNDAI MOTOR AMERICA
Install the radiator upper hose (A) and lower hose (B).

Fig 56: Identifying Radiator Upper Hose
Courtesy of HYUNDAI MOTOR AMERICA

Fig 57: Identifying Radiator Lower Hose
Courtesy of HYUNDAI MOTOR AMERICA
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose (E) and air cleaner assembly (F).
  Tightening torque
  
  Hose clamp:
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner bolts:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Connect the vacuum hose (D).
3. Connect the breather hose (C).
4. Connect the MAFS connector (B).
5. Install the air duct (A)
  
  Fig 58: Identifying Intake Air Hoses And Air Cleaner Assembly Components
  Courtesy of HYUNDAI MOTOR AMERICA
Install the engine cover (A), engine side covers (B) and the radiator grill upper cover (C).

Fig 59: Identifying Engine Cover, Engine Side Covers And Radiator Grill Upper Cover
Courtesy of HYUNDAI MOTOR AMERICA
Connect the battery negative cable.
Tightening torque:

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
  - After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
  - Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
  - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
  - Put radiator cap on tightly, then run the engine again and check for leaks.