Repair procedures: Removal

Engine removal is not required for this procedure.

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.

WARNING: In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

Remove the engine cover.
Disconnect the battery negative terminal (A).

Fig 1: Identifying Battery Negative Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Remove the air cleaner assembly.
1. Remove the air duct (A).
2. Disconnect the breather hose (B).
3. Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
  
  Fig 2: Identifying Air Duct, Breather Hose, Air Intake Hose And Air Cleaner Assembly
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the RH front wheel.
Remove the under covers (A).

Fig 3: Identifying Under Cover
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).

Fig 4: Identifying A/C Compressor Switch Connector, Alternator Connector And Alternator "B" Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).

Fig 5: Identifying Intake And Exhaust Oil Control Valve Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).

Fig 6: Identifying Ignition Coil, Injector Extension, Variable Intake System And Purge Control Solenoid Valve Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).

Fig 7: Identifying Fuel Pressure Control Valve, Intake And Exhaust Camshaft Position Sensor Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the oxygen sensor connectors (A) and the condenser connector (B).

Fig 8: Identifying Oxygen Sensor Connectors And Condenser Connector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the fuel hose (A) and the PCV (Positive crankcase ventilation) hose (B).

Fig 9: Identifying Fuel Hose And Positive Crankcase Ventilation Hose
Courtesy of HYUNDAI MOTOR AMERICA
Remove the vacuum pipe assembly (A).

Fig 10: Identifying Vacuum Pipe Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Remove the high pressure pipe (A)

Fig 11: Identifying High Pressure Pipe
Courtesy of HYUNDAI MOTOR AMERICA
Remove the high pressure fuel pump (A) and the roller tappet (B).

Fig 12: Identifying High Pressure Fuel Pump And Roller Tappet
Courtesy of HYUNDAI MOTOR AMERICA
Remove the ignition coils (A).

Fig 13: Identifying Ignition Coils
Courtesy of HYUNDAI MOTOR AMERICA
Remove the exhaust OCV (Oil control valve) (B).

Fig 14: Identifying Exhaust Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cylinder head cover (A) with gaskets (B).

Fig 15: Identifying Cylinder Head Cover And Gaskets
Courtesy of HYUNDAI MOTOR AMERICA
Remove the exhaust OCV (Oil control valve) adapter (A).

Fig 16: Identifying Exhaust Oil Control Valve Adapter
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the water pump pulley bolt and the drive idler mounting bolt.
Loosen the alternator tension adjusting bolt (A) to loosen tension.

Fig 17: Identifying Alternator Tension Adjusting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the alternator drive belt (A).

Fig 18: Identifying Alternator Drive Belt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the alternator (A).

Fig 19: Identifying Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the ground line (A) and then remove the engine mounting support bracket (A).

Fig 20: Identifying Engine Mounting Support Bracket And Ground Line
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Support the engine with a jack not to be tilted.
Remove the alternator bracket (B).
Remove the engine support bracket (A).

Fig 21: Identifying Engine Support Bracket And Alternator Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the water pump pulley (A) and the drive belt idler (B).

Fig 22: Identifying Water Pump Pulley And Drive Belt Idler
Courtesy of HYUNDAI MOTOR AMERICA
Remove the water pump (A).

Fig 23: Identifying Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.

Fig 24: Aligning Crankshaft Pulley Groove With Timing Mark Of Timing Chain Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the crankshaft bolt (B) and crankshaft pulley (A).

Fig 25: Identifying Crankshaft Pulley And Bolt
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 26: Holding Ring Gear Using SST (09231-2B100)
  Courtesy of HYUNDAI MOTOR AMERICA
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the bracket (A).
  
  Fig 27: Identifying Bracket
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 28: Identifying Dust Cover And Transaxle Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
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. Adjust the angle of the links (D), and fasten the bolt 70mm (2.7559in) in the original mounted hole.
  
  Fig 29: Identifying Ring Gear, Holder, Nuts And Links
  Courtesy of HYUNDAI MOTOR AMERICA
5. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 30: Tightening Holder And Links Securely Bolts And Nuts Using SST (09231-3D100)
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the timing chain cover (A).

Fig 31: Identifying Timing Chain Cover
Courtesy of HYUNDAI MOTOR AMERICA
Align the timing marks of the CVVT sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.
1. Check the dowel pin of the crankshaft for facing upside of the engine at this monent.
  CAUTION: Put paint marks on the timing chain links (3 places) that meet with the timing marks of the CVVT sprockets (In, Ex: 2) and the CVVT sprocket.
  
  Fig 32: Identifying Paint Marks On Timing Chain Links
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 33: Identifying Timing Marks On CVVT Sprockets
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the hydraulic tensioner (A).

Fig 34: Identifying Hydraulic Tensioner And Dowel Pin
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Before removing the tensioner, fix the piston of the tensioner with a pin through the hole (B) at compressed position.
Remove the timing chain tensioner arm (A) and guide (B).

Fig 35: Identifying Timing Chain Tensioner Arm And Guide
Courtesy of HYUNDAI MOTOR AMERICA
Remove the timing chain (A).

Fig 36: Identifying Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA