Repair procedures: Installation

Dowel pin of crankshaft should be positioned at 3° in relation to vertical center line.

Fig 1: Identifying Crankshaft Dowel Pin Position
Courtesy of HYUNDAI MOTOR AMERICA
Align the TDC marks (A) of the CVVT sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.

Fig 2: Identifying TDC Marks On CVVT Sprockets
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Install the new O-rings (A).

Fig 3: Identifying O-Rings
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Install the timing chain guide (A) and the timing chain (B).
Tightening torque:

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

Fig 4: Identifying Timing Chain Guide And Timing Chain
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain. Order: Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket.
Install the chain tensioner arm (A).
Tightening torque:

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

Fig 5: Identifying Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR AMERICA
Install the hydraulic tensioner (A) and remove the pin (B).
Tightening torque:

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

Fig 6: Identifying Hydraulic Tensioner And Dowel Pin
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Recheck the top dead center (TDC) marks on the crankshaft and camshaft.
Install the timing chain cover.
1. Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
2. Apply the liquid gasket (TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.
  Width : 3 ~ 5mm (0.1181~0.1969in.)
3. Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts (A) of the timing chain cover and Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the rest parts (B). Reassemble the cover within 5 minutes.
  Width : 3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
  
  Fig 7: Identifying Liquid Gasket Applying Areas On Water Pump Components
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Remove oil or dust on the surface surely.
4. Align the dowel pin of the cylinder block and the holes of the oil pump.
5. Tighten the bolts to install the timing chain cover (A).
  Tightening torque
  
  M8 bolts:
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  M6 bolts:
  
  9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 8: Identifying Timing Chain Cover
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: After the installation, do not crank engine or apply pressure on the cover for half an hour.
Using the SST (09455-21200), reassemble the timing chain cover oil seal.

Fig 9: Assembling Timing Chain Cover Oil Seal Using SST (09455-21200)
Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft pulley (A).
Tightening torque:

NOTE: For additional crankshaft pulley bolt torque information, refer to GAMMA ENGINE CRANKSHAFT PULLEY BOLT INFORMATION .

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

Fig 10: Identifying Crankshaft Pulley
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 11: 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 12: Identifying Bracket
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 13: 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 14: 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 15: Tightening Holder And Links Mounting Nuts And Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 16: Identifying Pulley Groove Position
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump (A) with a gasket.
Tightening torque:

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

Fig 17: Identifying Water Pump
Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque:
1. 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
  
  Fig 18: Identifying Water Pump Pulley And Drive Belt Idler
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Tighten the bolts diagonally.
Install the engine support bracket (A).
Tightening torque:

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
Install the alternator bracket (B).
Tightening torque:

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

Fig 19: Identifying Engine Support Bracket And Alternator Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Install the engine mounting support bracket (B) and connect the ground cable (A)
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)

Fig 20: Identifying Engine Mounting Support Bracket, Ground Cable, Mounting Bolts And Nuts
Courtesy of HYUNDAI MOTOR AMERICA
Install the alternator (A).
Tightening torque

M8 bolt:

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

M10 bolt:

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

Fig 21: Identifying Alternator
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt (A).

Fig 22: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR AMERICA
Adjust tension by tightening the alternator tension adjust bolt (A). (Refer to CHARGING SYSTEM ).
Tension

New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)

Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)

Fig 23: Identifying Alternator Tension Adjust Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
After applying the liquid gasket, Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.
Width : 2.0 ~ 2.5mm (0.0787~0.0984in.)

Fig 24: Identifying Liquid Gasket Applying Areas On Cylinder Head Cover
Courtesy of HYUNDAI MOTOR AMERICA
Install the OCV (Oil Control Valve) adapter (A).
Tightening torque:

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

Fig 25: Identifying Oil Control Valve Adapter
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- Keep the OCV adapter clean.
- Make sure the O-rings on the front bearing cap are installed.
Install the cylinder head cover (A) with a new gasket (B).

Fig 26: Identifying Cylinder Head Cover And Gasket
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Do not reuse the disassembled gasket.
Tighten the cylinder head cover bolts with the order and steps.
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 27: Identifying Cylinder Head Cover Bolts Tightening Sequence
Courtesy of HYUNDAI MOTOR AMERICA
Install the exhaust OCV (Oil Control Valve) (A).
Tightening torque:

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

Fig 28: Identifying Exhaust Oil Control Valve
Courtesy of HYUNDAI MOTOR AMERICA
Install the ignition coils (A).
Tightening torque:

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

Fig 29: Identifying Ignition Coils
Courtesy of HYUNDAI MOTOR AMERICA
Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to HIGH PRESSURE FUEL PUMP )
Tightening torque:

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

Fig 30: Identifying High Pressure Fuel Pump And Roller Tappet
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

NOTE: Do not use already used bolt again.

NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.

CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

CAUTION: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

Fig 31: Identifying High Pressure Fuel Pump O-Ring, Roller Tappet And Protrusion
Courtesy of HYUNDAI MOTOR AMERICA
Install the high pressure pipe (A). (Refer to DELIVERY PIPE )
Tightening torque:

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

Fig 32: Identifying High Pressure Pipe
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Do not reuse the high pressure pipe.
Install the vacuum pipe assembly (A).
Tightening torque:

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

Fig 33: Identifying Vacuum Pipe Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Connect the fuel hose (A) and the PCV (Positive crankcase ventilation) hose (B).

Fig 34: Identifying Fuel Hose And Positive Crankcase Ventilation Hose
Courtesy of HYUNDAI MOTOR AMERICA
Connect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B), the exhaust CMPS (Camshaft position sensor) connector (C).

Fig 35: Identifying Fuel Pressure Control Valve & Intake And Exhaust Camshaft Position Sensor Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Connect the oxygen sensor connectors (A), the condenser connector (B).

Fig 36: Identifying Oxygen Sensor Connectors And Condenser Connector
Courtesy of HYUNDAI MOTOR AMERICA
Connect 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 37: Identifying Ignition Coil, Injector Extension, Variable Intake System And Purge Control Solenoid Valve Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Connect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).

Fig 38: Identifying Intake And Exhaust Oil Control Valve Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Connect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).
Tightening torque:

9.8 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.8lb-ft)

Fig 39: Identifying A/C Compressor Switch Connector, Alternator Connector And Alternator "B" Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Install the under covers (A).
Tightening torque:

6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 7.9lb-ft)

Fig 40: Identifying Under Covers
Courtesy of HYUNDAI MOTOR AMERICA
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (D) and connect the air intake hose (C).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Connect the breather hose (B).
3. Install the air duct (A).
  
  Fig 41: Identifying Air Cleaner Assembly Components
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  - Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
  Fig 42: Identifying Air Intake Hose
  Courtesy of HYUNDAI MOTOR AMERICA
Connect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

Fig 43: Identifying Battery Negative Terminal
Courtesy of HYUNDAI MOTOR AMERICA
Install the engine cover.
CAUTION: Make sure the engine cover is installed before driving.