Repair procedures: Installation

Install the jack to the upper oil pan.

Fig 1: Locating Upper Oil Pan
Courtesy of HYUNDAI MOTOR CO.
The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 2: Identifying Timing Mark On Timing Chain Cover And Key
Courtesy of HYUNDAI MOTOR CO.
Install the tensioner adapter assembly(A).

Fig 3: Identifying Tensioner Adapter Assembly
Courtesy of HYUNDAI MOTOR CO.
Install the crankshaft sprocket(A) (LH camshaft drive).

Fig 4: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Install the LH timing chain guide(A).
Tightening torque

19.60 ~ 24.50N.m (2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

Fig 5: Identifying LH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Install the LH timing chain.
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.

Fig 6: Identifying Timing Mark On LH Timing Chain (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.

Fig 7: Identifying Timing Mark On LH Timing Chain (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.
Install the LH timing chain tensioner arm(B).
Tightening torque

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
Install the chain tensioner(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 8: Identifying LH Timing Chain Tensioner Arm And Chain Tensioner
Courtesy of HYUNDAI MOTOR CO.
Install the LH cam-to-cam guide(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 9: Identifying LH Cam-To-Cam Guide
Courtesy of HYUNDAI MOTOR CO.
Install the crankshaft sprocket(A) (O/P & RH camshaft drive).

Fig 10: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump chain(B) and the oil pump sprocket(A).
Tightening torque

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

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

19.60 ~ 24.50N.m (2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

Fig 12: Identifying RH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Install the RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.

Crankshaft sprocket → 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.

Fig 13: Identifying Timing Mark On RH Timing Chain (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.

Fig 14: Identifying Timing Mark On RH Timing Chain (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.
Install the RH timing chain tensioner arm(B).
Tightening torque

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
Install the RH timing chain auto tensioner(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 15: Identifying RH Timing Chain Tensioner Arm And Auto Tensioner
Courtesy of HYUNDAI MOTOR CO.
Install the RH cam-to-cam guide(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 16: Identifying RH Cam-To-Cam Guide
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump chain guide(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 17: Identifying Oil Pump Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump chain tensioner assembly(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 18: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of HYUNDAI MOTOR CO.
Pull out the pins of hydraulic tensioner (LH & RH).

Fig 19: Pulling Out Pins Of Hydraulic Tensioner (LH)
Courtesy of HYUNDAI MOTOR CO.

Fig 20: Pulling Out Pins Of Hydraulic Tensioner (RH)
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump chain cover(A).
Tightening torque

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 21: Identifying Oil Pump Chain Cover
Courtesy of HYUNDAI MOTOR CO.
After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
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 22: Identifying Sealant Applying Area On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
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.
  
  Bead width: 2.5mm(0.1in.)
  
  Fig 23: Identifying Sealant Applying Area On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
4. Install the new gasket(A) to the timing chain cover.
  
  Fig 24: Identifying Timing Chain Cover Gasket
  Courtesy of HYUNDAI MOTOR CO.
  
  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
  
  B(17):
  
  18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
  
  C(4):
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  D(1):
  
  58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
  
  E(1):
  
  58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
  
  F(2):
  
  24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft)
  
  G(4):
  
  21.56 ~ 23.52N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
  
  H(1):
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  I(1):
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  J(1):
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  K(4):
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  L(1):
  
  21.56 ~ 26.46N.m (2.2 ~ 2.7kgf.m, 15.91 ~ 19.53lb-ft)
  - New bolt
  Fig 25: Identifying Timing Chain Cover Bolts
  Courtesy of HYUNDAI MOTOR CO.
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 pulley(A).
Tightening torque

7.84 ~ 9.80N.m (0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

Fig 26: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt auto tensioner(A).
Tightening torque

Bolt(B):

81.39 ~ 85.32N.m (8.3 ~ 8.7kgf.m, 60.03 ~ 62.93lb-ft)

Bolt(C):

17.64 ~ 21.56N.m (1.8 ~ 2.2kgf.m, 13.02 ~ 15.91lb-ft)

Fig 27: Identifying Drive Belt Auto Tensioner With Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt idler(A).
Tightening torque

52.92 ~ 57.82N.m (5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft)

Fig 28: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR CO.
Install the alternator(A).
Tightening torque

26.48 ~ 33.34N.m (2.7 ~ 3.4kgf.m, 19.53 ~ 24.59lb-ft)

Fig 29: Identifying Alternator
Courtesy of HYUNDAI MOTOR CO.
Install the air conditioner compressor(A). (Refer to COMPRESSOR )

Fig 30: Identifying Air Conditioner Compressor
Courtesy of HYUNDAI MOTOR CO.
Install the power steering pump(A). (Refer to HYDRAULIC POWER STEERING SYSTEM )

Fig 31: Identifying Power Steering Pump
Courtesy of HYUNDAI MOTOR CO.
Lower the engine assembly by using the jack.
Using SST(09231-3C100), install timing chain cover oil seal.

Fig 32: Installing Timing Chain Cover Oil Seal Using SST(09231-3C100)
Courtesy of HYUNDAI MOTOR CO.
Using SST(09231-3C300) install the crankshaft damper pulley(A).
Tightening torque

284.2~303.8N.m (29.0~31.0kgf.m, 209.76~224.22lb-ft)

Fig 33: Identifying Crankshaft Damper Pulley
Courtesy of HYUNDAI MOTOR CO.

Fig 34: Installing Crankshaft Damper Pulley Using SST(09231-3C300)
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt(A).
Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley → tensioner pulley.

Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.

After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Fig 35: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR CO.
Install 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 36: Identifying Sealant Applying Area On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
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
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 37: Identifying Cylinder Head Cover Bolts
  Courtesy of HYUNDAI MOTOR CO.
  
  CAUTION: Do not reuse cylinder head cover gasket.
5. Install the ignition coil.
6. Connect the RH ignition coil connector(A), the condenser connector(B) and install the wiring bracket(C).
  
  Fig 38: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
  Courtesy of HYUNDAI MOTOR CO.
7. Install the connector bracket(A) from the LH cylinder head cover.
  
  Fig 39: Identifying LH Cylinder Head Cover Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
Install the surge tank.
1. Install the surge tank(A).
  Tightening torque
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  [3.3L]
  
  Fig 40: Identifying Surge Tank (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 41: Identifying Surge Tank (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
2. Install the connector bracket(A) on the surge tank.
  Tightening torque
  
  6.86 ~ 10.78N.m (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)
  
  Fig 42: Identifying Surge Tank Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
3. Install the surge tank stay.
  Tightening torque
  
  27.44 ~ 31.36N.m (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)
  
  [3.3L]
  
  Fig 43: Identifying Surge Tank Stay (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 44: Identifying Surge Tank Stay (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
4. Connect the brake vacuum hose.
5. Connect the PCV hose(C).
6. Connect the water hoses(B) to the ETC.
7. Install the ETC bracket(A).
  Tightening torque
  
  15.68 ~ 25.48N.m (1.6 ~ 2.6kgf.m, 11.57 ~ 18.80lb-ft)
  
  Fig 45: Identifying ETC Bracket, Water Hoses And PCV Hose
  Courtesy of HYUNDAI MOTOR CO.
8. Connect the PCSV connector(A), the MAP sensor connector(B) and the PCSV hose(C).
  [3.3L]
  
  Fig 46: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 47: Identifying PCSV Connector, MAP Sensor Connector And PCSV Hose (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
9. Connect the ETC connector(A) and the knock sensor connector(B).
  
  Fig 48: Identifying ETC Connector And Knock Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
10. Connect the LH CMPS(A) and oil pressure switch connector(B).
  
  Fig 49: Identifying LH CMPS And Oil Pressure Switch Connector
  Courtesy of HYUNDAI MOTOR CO.
11. Install the wiring harness protector(E), and connect the LH ignition connector(A), injector connector(B), condenser connector(C) and ground(D).
  
  Fig 50: Identifying LH Ignition Coil, Injector, Condenser Connectors, Wiring Harness Protector And Ground
  Courtesy of HYUNDAI MOTOR CO.
12. Connect the OCV connector(A) and knock sensor connector(B).
13. Connect the LH front oxygen sensor connector(C), alternator connector(B) and air compressor connector(E).
  
  Fig 51: Identifying OCV, Knock Sensor, LH Front Oxygen Sensor, Alternator And Air Compressor Connectors
  Courtesy of HYUNDAI MOTOR CO.
14. Connect the RH injector connector (A) and the ignition coil connector(B).
  [3.3L]
  
  Fig 52: Identifying RH Injector Connector And Ignition Coil Connector (3.3L)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 53: Identifying RH Injector Connector And Ignition Coil Connector (3.8L)
  Courtesy of HYUNDAI MOTOR CO.
15. Connect the power steering oil pressure sensor connector(A).
  
  Fig 54: Identifying Power Steering Oil Pressure Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
16. Connect the RH oxygen sensor connector(A) and VIS solenoid valve connector(B).
  
  Fig 55: Identifying RH Oxygen Sensor Connector And VIS Solenoid Valve Connector
  Courtesy of HYUNDAI MOTOR CO.
17. Connect the RH oxygen sensor connector(A).
  [3.3L]
  
  Fig 56: Identifying RH Oxygen Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
Install the no. 1 engine mounting (A) through the lower position of A/C pipe line.
Tightening torque

49.03 ~ 63.74N.m (5.0 ~ 6.5kgf.m, 36.17 ~ 47.01lb-ft)

Fig 57: Identifying No. 1 Engine Mounting
Courtesy of HYUNDAI MOTOR CO.
Install the A/C pipe bracket mounting bolt (A).

Fig 58: Identifying A/C Pipe Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR CO.
Install the engine coolant reservoir tank (A).
Install the engine mounting bracket (B).
Tightening torque

63.74 ~ 83.36N.m (6.5 ~ 8.5kgf.m, 47.01 ~ 61.48lb-ft)

Fig 59: Identifying Engine Coolant Reservoir Tank And Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Install the transaxle mounting bolts(A).
Tightening torque

49.03 ~ 63.74N.m (5.0 ~ 6.5kgf.m, 36.17 ~ 47.01lb-ft)

Fig 60: Identifying Transaxle Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the jack from the upper oil pan.

Fig 61: Locating Upper Oil Pan
Courtesy of HYUNDAI MOTOR CO.
Install the lower oil pan.
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.).
  
  But marked area(*) to be 5.0mm(0.2in.)
  
  Fig 62: Identifying Liquid Sealant Applying Area On Lower Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  CAUTION:
  - Make 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

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 63: Identifying Oil Pan
Courtesy of HYUNDAI MOTOR CO.
Install the upper radiator hose(A).

Fig 64: Identifying Upper Radiator Hose
Courtesy of HYUNDAI MOTOR CO.
Install the side cover(A).

Fig 65: Identifying RH Front Wheel Side Cover
Courtesy of HYUNDAI MOTOR CO.
Install the under cover(A).

Fig 66: Identifying RH Front Wheel Under Cover
Courtesy of HYUNDAI MOTOR CO.
Install the front wheels.
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose(C) and air cleaner(D).
2. Connect the ECM connector. (Refer to COMPONENTS AND COMPONENTS LOCATION )
3. Connect the breather hose(B) to air cleaner hose.
4. Connect the AFS connector(A).
Fig 67: Identifying AFS Connector, Breather Hose, Intake Air Hose And Air Cleaner
Courtesy of HYUNDAI MOTOR CO.
Install the air duct.

Fig 68: Identifying Air Duct
Courtesy of HYUNDAI MOTOR CO.
Install the engine cover.
Connect the negative terminal to the battery.

NOTE:

Refill engine with engine oil.
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.