Repair procedures: Installation

Tightening torque: 

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 3: Timing Chain Guide

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Tightening torque: 

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 4: Timing Chain Tensioner Arm

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Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D)

1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
   Fig 5: Timing Chain

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   NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.
2. Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.
   Fig 6: Timing Chain On Exhaust CVVT Sprocket

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   NOTE:

   • The timing mark of the exhaust CVVT sprocket should be matched with timing mark (color link) of timing chain when installing the timing chain.
   • Press down the timing chain links on the exhaust CVVT sprocket to prevent the sprocket from spinning.

Tightening torque: 

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

Fig 7: Timing Chain Auto Tensioner And Stopper Pin

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Fig 8: Tensioner Arm And Tensioner Housing

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1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
3. Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.

   Bead width:  3.0 ~ 5.0 mm (0.11 ~ 0.20 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 10: Timing Chain Cover Bead

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4. After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path from oil leakage.

   Bead width 

   Whole section: 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)

   Section A: 4.5 ~ 5.5 mm (0.18 ~ 0.22 in.)

   Section B: 8.0 ~ 9.0 mm (0.32 ~ 0.35 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 11: Sealant Application Area On Timing Chain Cover

   Courtesy of HYUNDAI MOTOR AMERICA
5. Install the timing chain cover. 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 in exact position.

   Tightening torque 

   Bolts (A, B):

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

   Bolt (C):

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

   Bolts (D, E):

   39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)

   Bolt (F):

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

   Fig 12: Timing Chain Cover Bolts Identification

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   CAUTION: Do not reuse the seal bolts (C, F).
   CAUTION: The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.

1. Apply engine oil on the edge of new oil seal.
   CAUTION: Remove any debris from the lip portion of the oil seal.
2. Install the front oil seal using SST (09231-2E000).
   Fig 13: Installing Front Oil Seal Using SST (09231-2E000)

   Courtesy of HYUNDAI MOTOR AMERICA

Tightening torque: 

196.1 ~ 205.9 N.m (20.0 ~ 21.0 kgf.m, 144.7 ~ 151.9 lb-ft)

Fig 14: Installing Crankshaft Damper Pulley

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Tightening torque: 

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

Fig 20: Water Pump Pulley

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Tightening torque: 

34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)

Fig 21: Front Engine Hanger

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1. Preassemble the alternator (A) temporarily.
   Fig 22: Alternator And Bolts

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2. Install the drive belt (C).
3. Adjust the tension by turning the tension adjusting bolt (B) clockwise.

   (Refer to "ALTERNATOR ")

   Belt tension 

   New belt:

   637.4 ~ 735.5 N (65 ~ 75 kgf, 143.3 ~ 165.3 lb-ft)

   Used belt:

   441.3 ~ 539.4 N (45 ~ 55 kgf, 99.2 ~ 121.3 lb-ft)

   Fig 23: Engine Drive Belt Routing

   Courtesy of HYUNDAI MOTOR AMERICA
4. Tighten the alternator mounting bolts with the specified torque.

   Tightening torque 

   M10 bolt:

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

   M8 bolt:

   21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)

1. Install the engine mounting support bracket (B).

   Tightening torque 

   Nut (C):

   63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

   Bolt (D) and Nuts (E):

   49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

2. Connect the engine ground line (A).
   Fig 24: Engine Mounting Support Bracket, Engine Ground Line, Bolts And Nuts

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3. Remove the jack from the lower crankcase.

(Refer to ENGINE LUBRICATION SYSTEM )

1. The hardening sealant located on the cylinder head cover and the gap between the timing chain cover and the cam carrier should be removed before assembling cylinder head cover.
2. Apply engine oil on the lip portion of the oil seal on the cover and outer surface of the spark plug pipes.
3. After applying sealant on the gap between the timing chain cover and the cam carrier, it should be assembled within 5 minutes.

   Bead width:  2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 25: Gap Between Timing Chain Cover And Cam Carrier

   Courtesy of HYUNDAI MOTOR AMERICA
4. Install the cylinder head cover (A) by tightening the bolts, in several passes, in the sequence as shown below.

   Tightening torque 

   1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

   Fig 26: Cylinder Head Cover Bolts Tightening Sequence

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   CAUTION:

   • Do not reuse cylinder head cover gasket.
   • Before installing the cylinder head cover, make sure the cylinder head cover gasket is not separated from the cylinder head cover gasket groove.
   • The engine running or pressure test should not be performed within 30 minutes after the cylinder head cover was assembled.

Tightening torque: 

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

Fig 28: Ignition Coils

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1. The intake OCV (Oil control valve) connector (A)
   Fig 31: Intake OCV (Oil Control Valve) Connector

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2. The exhaust OCV (Oil control valve) connector (A)
   Fig 32: Exhaust OCV (Oil Control Valve) Connector

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3. The alternator connector (A)
   Fig 33: Alternator Connector

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4. The ignition coil connectors (A)
   Fig 34: Ignition Coil Connectors

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5. The intake CMPS (Camshaft position sensor) connector (A)
6. The exhaust CMPS (Camshaft position sensor) connector (B)
   Fig 35: Intake And Exhaust CMPS (Camshaft Position Sensor) Connectors

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(Refer to ENGINE AND TRANSAXLE ASSEMBLY )

(Refer to ENGINE AND TRANSAXLE ASSEMBLY )

(Refer to "WHEEL ")

(Refer to ENGINE AND TRANSAXLE ASSEMBLY )