Repair Procedures: Installation

Install the balance shaft chain (Oil pump chain). (Refer to LUBRICATION SYSTEM )
Install the crankshaft chain sprocket (B).
Install the timing chain oil jet (A).
Tightening torque:

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

Fig 1: Identifying Timing Chain Oil Jet And Crankshaft Chain Sprocket
Courtesy of HYUNDAI MOTOR CO.
Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 2: Identifying Crankshaft Key

G00517308

Courtesy of HYUNDAI MOTOR CO.

Fig 3: Identifying TDC Marks Of Intake & Exhaust CVVT Sprockets

G00517309

Courtesy of HYUNDAI MOTOR CO.

Install the timing chain guide (A).
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
Courtesy of HYUNDAI MOTOR CO.
Install the timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT assembly (C) → Exhaust CVVT assembly (D).

The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 5: Identifying Timing Chain Mark
Courtesy of HYUNDAI MOTOR CO.

Fig 6: Identifying Timing Sprockets Mark
Courtesy of HYUNDAI MOTOR CO.

Fig 7: Identifying Timing Chain Guide, Crankshaft Sprocket And Intake CVVT Assembly
Courtesy of HYUNDAI MOTOR CO.
Install the timing chain tensioner arm (B).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Install the timing chain auto tensioner (A) and remove the set pin.
Tightening torque:

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

Fig 8: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR CO.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

Fig 9: Identifying Timing Mark
Courtesy of HYUNDAI MOTOR CO.
Install timing chain cover.
1. Using a gasket scraper, remove all the old gasket material from the gasket surfaces.
2. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and ETC.
3. Before assembling the timing chain cover, the liquid sealant Loctite 5900H or THREEBOND 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: 3.0 mm (0.12 in.)
  
  Fig 10: Identifying Gap Between Cylinder Head And Cylinder Block
  Courtesy of HYUNDAI MOTOR CO.
4. After applying liquid sealant Loctite 5900H or THREE BOND 1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity.
  Bead width: 3.0 mm (0.12 in.)
  
  Fig 11: Identifying Liquid Sealant Applying Area On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
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:
  
  6x25: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  8x28: 18.6 ~ 22.5 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
  
  10x45: 39.2 ~ 44.1 N.m (4.0 ~ 4.5 kgf.m, 28.9 ~ 32.5 lb-ft)
  
  10x40: 39.2 ~ 44.1 N.m (4.0 ~ 4.5 kgf.m, 28.9 ~ 32.5 lb-ft)
  
  Fig 12: Identifying Dowel Pins On Cylinder Block And Holes
  Courtesy of HYUNDAI MOTOR CO.
6. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the 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 Loctite 5900H or THREEBOND 1217H should be applied on oil pan.
  The part must be assembled within 5 minutes after the sealant was applied.
  
  Bead width: 3.0 mm (0.12 in)
  
  Fig 13: Identifying Liquid Sealant Applying Area On Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
  CAUTION:
  - 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 oil pan (A).
  Uniformly tighten the bolts in several passes.
  
  Tightening torque:
  
  M9 (B): 30.4 ~ 34.3 N.m (3.1 ~ 3.5 kgf.m, 22.4 ~ 25.3 lb-ft)
  
  M6 (C): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 14: Identifying Oil Pan And Bolts
  Courtesy of HYUNDAI MOTOR CO.
4. After assembly, wait at least 30 minutes before filling the engine with oil.
Install the cylinder head cover.
1. The hardened 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 (Loctite 5900H), it should be assembled within 5 minutes.
  Bead width: 2.5 mm (0.1 in.)
  
  Fig 15: Identifying Cylinder Head Cover
  Courtesy of HYUNDAI MOTOR CO.
3. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
4. Install the cylinder head cover bolts in the following sequence.
  Tightening torque:
  
  Step 1: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
  
  Step 2: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 16: Identifying Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR CO.
  
  CAUTION: Do not reuse cylinder head cover gasket.
Install the breather hose (A).

Fig 17: Identifying Breather Hose
Courtesy of HYUNDAI MOTOR CO.
Connect the PCV hose (A) and exhaust OCV connector (B).
Install the ignition coils and then connect the ignition coil connectors (C).

Fig 18: Identifying PCV Hose And Exhaust OCV Connector
Courtesy of HYUNDAI MOTOR CO.
Install the crankshaft pulley (B).
Tightening torque:

166.6 ~ 176.4 N.m (17.0 ~ 18.0 kgf.m, 122.9 ~ 130.1 lb-ft)
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 19: Identifying Special Tool And Ring Gear
  Courtesy of HYUNDAI MOTOR CO.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
  
  Fig 20: Identifying Dust Cover And Transaxle Mounting Bolts
  Courtesy of HYUNDAI MOTOR CO.
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
  
  Fig 21: Adjusting Angle Of Links
  Courtesy of HYUNDAI MOTOR CO.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 22: Identifying Special Tool (09231-3D100)
  Courtesy of HYUNDAI MOTOR CO.
Install the water pump pulley (A).
Tightening torque:

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

Fig 23: Identifying Water Pump Pulley
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt tensioner pulley (B).
Tightening torque:

53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)

NOTE: The tensioner pulley bolt has LEFT handed threads.
Install the idler (A).
Tightening torque:

53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)

Fig 24: Identifying Idler
Courtesy of HYUNDAI MOTOR CO.
Install the air compressor bracket (A).
Tightening torque:

19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 13.7 ~ 14.5 lb-ft)

Fig 25: Identifying Air Compressor Bracket
Courtesy of HYUNDAI MOTOR CO.
Install the air compressor lower bolts.
Tightening torque:

20.0 ~ 32.9 N.m (2.04 ~ 3.36 kgf.m, 14.8 ~ 24.3 lb-ft)

Fig 26: Identifying Air Compressor Lower Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt (A).
Crankshaft pulley -> A/C pulley -> Alternator pulley -> Idler pulley -> Idler pulley -> Water pump pulley -> Tensioner pulley. Rotate the auto tensioner counter - clockwise. With the tensioner turned, install the drive belt on auto tensioner and then release the tensioner.

Fig 27: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR CO.
Install the engine mounting bracket (A) and then connect the ground cable.
Tightening torque:

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Fig 28: Identifying Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Install the RH side cover.
Tightening torque:

8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 7.9 lb-ft)
Install the RH front wheel.
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Install the engine cover (B).
Reconnect the battery negative cable (A).
Tightening torque:

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

Fig 29: Identifying Battery Negative Cable And Engine Cover
Courtesy of HYUNDAI MOTOR CO.
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
  - After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
- 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 and let it cool down. 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.