Repair procedures: Installation

Install the tensioner adapter (A) and the timing chain guide bolts (B).
Tightening torque

Tensioner adapter bolts:

21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Timing chain guide bolts:

21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Fig 1: Identifying Tensioner Adapter And Timing Chain Guide Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft sprocket (A) with the friction plates (B).
NOTE: Completely fix the four friction plate clips and the sprocket groove.
Align the key-home of the friction plate with the key-home of the sprocket.
Be careful for the clip not to be folded.
The timing mark (yellow color) should be toward engine front.
The bigger side of crankshaft sprocket outer diametar [Ø45.7mm (1.7992in.)] should be toward crankshaft.
The block is placed at bottom up before install the timing chain system and timing chain cover assembly.

Fig 2: Identifying Crankshaft Sprocket And Friction Plates
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: The mark of friction plate should be placed top. (Engine is placed bottom up)

Fig 3: Identifying Mark Of Friction Plate
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil pump chain (B) with the oil pump sprocket (A).
Tightening torque:

21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Fig 4: Identifying Oil Pump Chain And Oil Pump Sprocket
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil pump tensioner (A).
Tightening torque:

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

Fig 5: Identifying Oil Pump Tensioner
Courtesy of HYUNDAI MOTOR AMERICA
Install the LH timing chain guide (A) and the chain (B). Insert the guide to the fixing pipe of guide bolt with the chain.

Fig 6: Identifying LH Timing Chain And Guide
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: The chain color link (yellow) should be toward engine front.
Align the timing mark of the friction plate and crankshaft sprocket.
Install the LH timing chain tensioner arm (A).
Tightening torque:

21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Fig 7: Identifying LH Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR AMERICA
Hold the LH timing chain, guide and arm using the timing chain locking tool (SST: 09231-2J600).

Fig 8: Holding LH Timing Chain Using Tool
Courtesy of HYUNDAI MOTOR AMERICA
Install the RH timing chain guide (A) and the chain (B). Insert the guide to the fixing pipe of guide bolt with the chain.

Fig 9: Identifying RH Timing Chain And Guide
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: The chain color link (yellow) should be toward engine front.
Align the timing mark of the fiction plate and crankshaft sprocket.
Install the RH timing chain tensioner arm (A).
Tightening torque:

21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Fig 10: Identifying RH Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR AMERICA
Hold the RH timing chain, guide and the arm using the timing chain locking tool (SST: 09231-2J600).

Fig 11: Holding RH Timing Chain Using Tool
Courtesy of HYUNDAI MOTOR AMERICA
Pull out the oil pump tensioner stopper pin, and make sure tension is set. And confirm the timing chain align mark again.

Fig 12: Pulling Out Oil Pump Tensioner Stopper Pin
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Confirm that the "shoe" area of oil pump tensioner is protruding.
Fiction plate mark, timing chain color link (yellow) and crankshaft sprocket mark (yellow) should be matched.
Install the timing chain lower cover.
NOTE: Assemble the timing chain lower cover with engine bottom up condition.
1. The sealant locations on chain lower cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
2. Install the new gasket (A) to the timing chain lower cover.
  
  Fig 13: Identifying Gasket Of Timing Chain Lower Cover
  Courtesy of HYUNDAI MOTOR AMERICA
3. Apply liquid sealant LT 5900H (Hyundai Gray RTV) or equivalent on timing chain lower cover. The part must be assembled within 5 minutes after sealant was applied.
  Sealant should be applied in a continuous bead in each of the areas indicated below.
  
  Bead width: Ø2.5 ± 0.5mm
  
  Fig 14: Identifying Wide Spot T-Joints
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Fig 15: Identifying Liquid Sealant Applying Area On Timing Chain Lower Cover
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - During timing chain lower cover installation, care not to take off applied sealant on the timing chain lower cover by contact with other parts.
  - Apply sealant in a 4.0 ± 0.5mm wide spot for the 4 T-joints (D).
4. The dowel pins on the cylinder block and holes on the timing chain lower cover should be used as a reference in order to assemble the timing chain lower cover to be in exact position.
  Tightening torque:
  
  23.5 ~ 25.5 N.m (2.4 ~ 2.6 kgf.m, 17.4 ~ 18.8 lb-ft)
  
  [Front]
  
  Fig 16: Identifying Dowel Pins On Cylinder Block (Front)
  Courtesy of HYUNDAI MOTOR AMERICA
  
  [Rear]
  
  Fig 17: Identifying Dowel Pins On Cylinder Block (Rear)
  Courtesy of HYUNDAI MOTOR AMERICA
5. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the cylinder head assembly.
(Refer to CYLINDER HEAD GASKET cylinder head assembly .

NOTE: Before install the cylinder head assembly, place the engine up right.
Install the camshaft and camshaft carrier assembly. (Refer to REMOVAL AND INSTALLATION cylinder head assembly )
Remove the SST from the timing chain guide and the timing chain tensioner arm.
Install the timing chain to the CVVT sprocket. (Refer to REMOVAL AND INSTALLATION cylinder head assembly )

Fig 18: Identifying Timing Mark Of CVVT Sprocket (LH)
Courtesy of HYUNDAI MOTOR AMERICA

Fig 19: Identifying Timing Mark Of CVVT Sprocket (RH)
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 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 (orange color link) of timing chain during installation.
Install the timing chain tensioner. (Refer to REMOVAL AND INSTALLATION cylinder head assembly )
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 O-ring (A) to the water temperature control assembly.

Fig 20: Identifying O-Ring Of Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the water temperature control assembly (A) and the water outlet fitting (B).
Tightening torque

Water temperature control assembly bolts:

16.7 ~ 19.6 N.m (1.7 ~ 2.0 kgf.m, 12.3 ~ 14.5 lb-ft)

Water outlet fitting bolts (M8):

16.7 ~ 19.6 N.m (1.7 ~ 2.0 kgf.m, 12.3 ~ 14.5 lb-ft)

Water outlet fitting bolt (M6):

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

Fig 21: Identifying Water Outlet Fitting And Water Temperature Control Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump (A) with a new gasket.
Tightening torque:

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

Fig 22: Identifying Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Using SST (09231-2J310, 09231-H1100), Install the front oil seal (A).

Fig 23: Installing Front Oil Seal
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft pulley (A).
Tightening torque:

127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lb-ft) + 90°~ 94°

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

Fig 24: Identifying Crankshaft Pulley
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Use the SST (09231-2B100, 09231-3N100) to install the crankshaft pulley bolt, after remove the starter.

Fig 25: Installing Crankshaft Pulley Bolt
Courtesy of HYUNDAI MOTOR AMERICA
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 (Hyundai Gray RTV) 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 26: Identifying Gasket Surfaces Of Upper Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  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 27: Identifying Upper Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 28: Upper Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
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 (Hyundai Gray RTV) 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 29: Identifying Gasket Surfaces Of Lower Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  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 (A).
  
  Fig 30: Identifying Lower Oil Pan
  Courtesy of HYUNDAI MOTOR AMERICA
  
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 31: Lower Oil Pan Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
Install the oil filter & cooler assembly (A).
Tightening torque:

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

Fig 32: Identifying Oil Filter And Cooler Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A).
Tightening torque:

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

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

Fig 33: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt tensioner (A).
Tightening torque:

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

Fig 34: Identifying Drive Belt Tensioner
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt idler (A).
Tightening torque:

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

Fig 35: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR AMERICA
Install the air conditioner compressor (A).
(Refer to REMOVAL AND INSTALLATION HA )

Fig 36: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator bracket (A).
Tightening torque

Bolts (B) 4EA:

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

Bolt (C) 1EA:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

Fig 37: Identifying Alternator Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator (A).
Tightening torque:

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

Fig 38: Identifying Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Install the removed parts.
(Refer to CYLINDER HEAD GASKET Cylinder Head Assembly installation procedure )