Repair Procedures: Installation

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

Fig 1: Locating Dowel Pin Of Crankshaft Should Positioned At 3° In Relation To Vertical Center Line
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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: Locating TDC Marks Of CVVT Sprockets With Upper Surface Of Cylinder Head
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Install the new O-rings (A).

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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)

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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)

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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)

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NOTE: Recheck the top dead center (TDC) marks on the crankshaft and camshaft.

Install the timing chain cover.

Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
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.)

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.)

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CAUTION: Remove oil or dust on the surface surely.

Align the dowel pin of the cylinder block and the holes of the oil pump.

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)

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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.

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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)

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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.

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Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.

Remove the bracket (A).

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Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).

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Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.

Adjust the angle of the links (D), and fasten the bolt 70mm (2.7559in) in the original mounted hole.

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Tighten the bolts and nuts of the holder and links securely.

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NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 3: Aligning Groove On Pulley

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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)

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Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque:

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

B: 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

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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)

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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)

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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)

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Install the drive belt (A).

Fig 4: Engine Drive Belt Routing Diagram
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Adjust tension by tightening the alternator tension adjust bolt (A).
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)

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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.)

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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)

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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).

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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 5: Cylinder Head Cover Bolts Tightening
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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)

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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)

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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)

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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 6: Applying Engine Oil To O-Ring Of High Pressure Fuel Pump, Roller Tappet & Protrusion
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Install the high pressure pipe (A). (Refer to HIGH PRESSURE FUEL PUMP )
Tightening torque:

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

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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)

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Connect the fuel hose (A) and the PCV (Positive crankcase ventilation) hose (B).

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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).

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Connect the oxygen sensor connectors (A), the condenser connector (B).

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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).

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Connect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).

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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)

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Install the under covers (A).
Tightening torque:

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

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Install the RH front wheel.

Install the air cleaner assembly.

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)
Connect the breather hose (B).

Install the air duct (A).

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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 7: Air Intake Hose Installation Position

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Connect the battery negative terminal (A).
Tightening torque:

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

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Install the engine cover.
CAUTION: Make sure the engine cover is installed before driving.