Repair procedures: Installation

WARNING: This page is about a different car, the 2011 Hyundai Veracruz. However, it is still accessible from the selected car via links, so may be relevant.

Install the jack to the upper oil pan.

Fig 1: Identifying 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 Key Of Crankshaft
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 ~ 24.50Nm (2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

Fig 5: Identifying LH Timing Chain Guide
Courtesy of HYUNDAI MOTOR CO.
Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.

Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket (C) → Intake camshaft sprocket (D).

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

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

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

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

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

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

9.80 ~ 11.76Nm (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) (Oil pump & RH camshaft drive).

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

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

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

19.60 ~ 24.50Nm (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 procedure below.

Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C).

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

Fig 13: Identifying Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.

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

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

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

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

9.80 ~ 11.76Nm (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 ~ 11.76Nm (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 ~ 11.76Nm (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 tensioners (LH & RH).

Fig 19: Pulling Out Pins Of Hydraulic Tensioners (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.

Fig 20: Pulling Out Pins Of Hydraulic Tensioners (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.
Install the oil pump chain cover (A).
Tightening torque

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

Fig 21: Identifying Oil Pump Chain Cover
Courtesy of HYUNDAI MOTOR CO.
After rotating 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 TB1217H 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 Locations On Chain Cover
  Courtesy of HYUNDAI MOTOR CO.
3. After applying liquid sealant TB1217H on the 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 Liquid Sealant Apply Area
  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 Cover Tightening Sequence
  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 ~ 9.80Nm (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
Courtesy of HYUNDAI MOTOR CO.
Install the drive belt idler (A).
Tightening torque

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

Fig 28: Identifying Drive Belt Idler
Courtesy of HYUNDAI MOTOR CO.
Lower the engine assembly by using the jack.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 29: Installing Timing Chain Cover Oil Seal
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 30: Installing Crankshaft Damper Pulley
Courtesy of HYUNDAI MOTOR CO.

NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3C300) to hold the ring gear after removing the starter.
  
  Fig 31: Identifying Special Tool
  Courtesy of HYUNDAI MOTOR CO.
  - Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the front muffler. (Refer to INTAKE AND EXHAUST SYSTEM ).
2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
  
  Fig 32: Identifying Dust Cover And Transaxle Mounting Bolts
  Courtesy of HYUNDAI MOTOR CO.
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. Fasten the two transaxle mounting bolts in the original mounted holes.
  
  Fig 33: Identifying Holder Nuts
  Courtesy of HYUNDAI MOTOR CO.
5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
  
  Fig 34: Identifying Holder Bolts and Nuts
  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 Apply Area
  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 Tightening Sequence
  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
  Courtesy of HYUNDAI MOTOR CO.
7. Install the connector bracket (A) from LH cylinder head cover.
  
  Fig 39: Identifying Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
Install the surge tank and wiring connectors.
1. Install the surge tank (A).
  Tightening torque
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 40: Identifying Surge Tank
  Courtesy of HYUNDAI MOTOR CO.
2. Install the connector bracket (A) to the surge tank.
  Tightening torque
  
  6.86 ~ 10.78N.m (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)
  
  Fig 41: Identifying Connector Bracket
  Courtesy of HYUNDAI MOTOR CO.
3. Install the surge tank stays (A).
  Tightening torque
  
  27.44 ~ 31.36N.m (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)
  
  Fig 42: Identifying Surge Tank Stays (1 Of 2)
  Courtesy of HYUNDAI MOTOR CO.
  
  Fig 43: Identifying Surge Tank Stays (2 Of 2)
  Courtesy of HYUNDAI MOTOR CO.
4. Install the breather pipe assembly (A).
  Tightening torque
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 44: Identifying Breather Pipe Assembly
  Courtesy of HYUNDAI MOTOR CO.
5. Connect the brake vacuum hose.
6. Connect the LH rear oxygen sensor connector (A).
  
  Fig 45: Identifying LH Rear Oxygen Sensor Connector
  Courtesy of HYUNDAI MOTOR CO.
7. Connect the TCU connector (A) and CKP sensor connector (B).
  
  Fig 46: Identifying TCU Connector
  Courtesy of HYUNDAI MOTOR CO.
8. Connect the water hoses (B) to the ETC and PCV (C) hose.
  
  Fig 47: Identifying Water Hoses
  Courtesy of HYUNDAI MOTOR CO.
9. Connect the ETC connector (A) and knock sensor connector (B).
  
  Fig 48: Identifying ETC Connector
  Courtesy of HYUNDAI MOTOR CO.
10. Connect the PCSV connector (A), the MAP sensor connector (B) and the PCSV hose.
  
  Fig 49: Identifying PCSV Connector
  Courtesy of HYUNDAI MOTOR CO.
11. Disconnect the RH CMPS (A) and the OTS connector (B).
  
  Fig 50: Identifying RH CMPS
  Courtesy of HYUNDAI MOTOR CO.
12. Install the wiring harness protector (E) and connect the LH ignition coil connector (A), the injector connector (B), the condenser connector (C) and the ground (D).
  
  Fig 51: Identifying LH Ignition Coil Connector
  Courtesy of HYUNDAI MOTOR CO.
13. Connect the alternator connector (D) and the air compressor connector (E).
14. Connect the LH front oxygen sensor connector (C).
15. Connect the OCV connector (A) and the knock sensor connector (B).
16. Connect the RH ignition coil connector.
  
  Fig 52: Identifying OCV Connector
  Courtesy of HYUNDAI MOTOR CO.
17. Disconnect the RH front and rear oxygen sensor connectors (A), the power steering sensor connector (B), the RH injector harness connector (C) and the VIS solenoid valve connector (D).
  
  Fig 53: Identifying Rear Oxygen Sensor Connectors
  Courtesy of HYUNDAI MOTOR CO.
Connect the ground cable (A) and tighten the power steering hose mounting bolt (B).

Fig 54: Identifying Ground Cable
Courtesy of HYUNDAI MOTOR CO.
Install the engine mounting bracket (A).
Tightening torque

B: 78.5 ~ 98.0N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)

C: 63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Fig 55: Identifying Engine Mounting Bracket
Courtesy of HYUNDAI MOTOR CO.
Tighten the relay box mounting bolts and install the PCM & relay box cover.

Fig 56: Identifying Relay Box Mounting Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove the jack from the upper oil pan.
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 TB1217H 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 57: Identifying Liquid Sealant Apply Area
  Courtesy of HYUNDAI MOTOR CO.
  CAUTION:
  1. Make clean the sealing face before assembling two parts.
  2. Remove harmful foreign matters on the sealing face before applying sealant.
  3. When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  4. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install the lower oil pan (A).
  Tightening torque
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 58: Identifying Lower Oil Pan
  Courtesy of HYUNDAI MOTOR CO.
Install the side cover.
Tightening torque

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)
Install the under cover (A).
Tightening torque

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)

Fig 59: Identifying Under Cover
Courtesy of HYUNDAI MOTOR CO.
Install the RH front wheel.
Tightening torque

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose (C) and air cleaner body (D).
2. Connect the breather hose (B) to the air cleaner hose.
3. Connect the AFS connector (A).
  
  Fig 60: Identifying AFS Connector
  Courtesy of HYUNDAI MOTOR CO.
Install the engine cover (A).

Fig 61: Identifying Engine Cover
Courtesy of HYUNDAI MOTOR CO.
Install the air duct (A).

Fig 62: Identifying Air Duct
Courtesy of HYUNDAI MOTOR CO.
Connect the battery negative cable (A).

Fig 63: Identifying Battery Negative Cable
Courtesy of HYUNDAI MOTOR CO.
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.