Engine removal is not
required for this procedure.
•
|
Use fender covers to avoid damaging
painted surfaces. |
•
|
To avoid damage, unplug the wiring
connectors carefully while holding the connector
portion. | |
Mark all wiring and hoses to avoid
misconnection. |
In case of removing the high pressure fuel
pump, high pressure fuel pipe, delivery pipe, and injector, there
may be injury caused by leakage of the high pressure fuel. So don’t
do any repair work right after engine stops.
|
1. |
Remove the engine
cover. |
2. |
Disconnect the battery negative terminal (A).

|
3. |
Remove the air cleaner assembly.
(1) |
Remove the air duct
(A). |
(2) |
Disconnect the breather hose
(B). |
(3) |
Disconnect the air intake hose (C) and
then remove the air cleaner assembly
(D). |

|
4. |
Remove the RH front wheel.
|
5. |
Remove the under covers (A).

|
6. |
Disconnect the A/C compressor switch connector
(A), the alternator connector (B) and the cable from the alternator
“B” terminal (C).

|
7. |
Disconnect the intake OCV (Oil control valve)
connector (A) and the exhaust OCV (Oil control valve) connector
(B).

|
8. |
Disconnect 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).

|
9. |
Disconnect the FPCV (Fuel pressure control
valve) connector (A), the intake CMPS (Camshaft position sensor)
connector (B) and the exhaust CMPS (Camshaft position sensor)
connector (C).

|
10. |
Disconnect the oxygen sensor connectors (A)
and the condenser connector (B).

|
11. |
Disconnect the fuel hose (A) and the PCV
(Positive crankcase ventilation) hose (B).

|
12. |
Remove the vacuum pipe assembly
(A).

|
13. |
Remove the high pressure pipe (A). (Refer to
FL group)

|
14. |
Remove the high pressure fuel pump (A) and the
roller tappet (B). (Refer to FL group)

|
15. |
Remove the ignition coils (A).

|
16. |
Remove the exhaust OCV (Oil control valve)
(B).

|
17. |
Remove the cylinder head cover (A) with
gaskets (B).

|
18. |
Remove the exhaust OCV (Oil control valve)
adapter (A).

|
19. |
Loosen the water pump pulley bolt and the
drive idler mounting bolt. |
20. |
Loosen the alternator tension adjusting bolt
(A) to loosen tension.

|
21. |
Remove the alternator drive belt
(A).

|
22. |
Remove the alternator (A). (Refer to Altemator
in EE Group).

|
23. |
Disconnect the ground line (A) and then remove
the engine mounting support bracket (A).

Support the engine with a jack not to be
tilted. | |
24. |
Remove the alternator bracket
(B). |
25. |
Remove the engine support bracket
(A).

|
26. |
Remove the water pump pulley (A) and the drive
belt idler (B).

|
27. |
Remove the water pump (A).

|
28. |
Turn the crankshaft pulley clockwise, and
align its groove with the timing mark of the timing chain
cover.

|
29. |
Remove the crankshaft bolt (B) and crankshaft
pulley (A).

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.

|
•
|
Install the SST (09231-3D100) to
hold the ring gear after removing the dust
cover. |
1. |
Remove the bracket
(A).

|
2. |
Remove the dust cover (A) and
unfasten the transaxle mounting bolt (B).

|
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.

|
5. |
Tighten the bolts and nuts of the
holder and links securely.

| | |
30. |
Remove the timing chain cover
(A).

|
31. |
Align the timing marks of the CVVT sprockets
with the upper surface of the cylinder head to make No.1 cylinder be
positioned at TDC.
(1) |
Check the dowel pin of the crankshaft
for facing upside of the engine at this monent.
Put paint marks on the timing
chain links(3 places) that meet with the timing marks of
the CVVT sprockets(In, Ex : 2) and the CVVT
sprocket. | |


|
32. |
Remove the hydraulic tensioner
(A).

Before removing the tensioner, fix the
piston of the tensioner with a pin through the hole(B) at
compressed
position. | |
33. |
Remove the timing chain tensioner arm (A) and
guide (B).

|
34. |
Remove the timing chain (A).

|
Sprockets, Hydraulic
Tensioner, Chain Guide, Tensioner Arm, Timing
Chain |
1. |
Check the CVVT sprocket, crankshaft sprocket
teeth for abnormal wear, cracks or damage. Replace if
necessary. |
2. |
Check a contact surface of the chain tensioner
arm and guide for abnormal wear, cracks or damage. Replace if
necessary. |
3. |
Check the hydraulic tensioner for its piston
stroke and ratchet operation. Replace if
necessary. |
4. |
Check the timing chain for its elongation,
abnormal wear or damage. Replace if
necessary. |
Belt, Idler, Pulley
1. |
Check the idler for excessive oil leakage,
abnormal rotation or vibration. Replace if
necssery. |
2. |
Check belt for maintenance and abnormal wear
of V-ribbed part. Replace if
necssery. |
3. |
Check the pulleys for vibration in rotation,
oil or dust deposit of V-ribbed part. Replace if
necssery.
•
|
Do not bend, twist or turn the
timing chain inside
out. |
•
|
Do not allow the timing chain to
come into contact with oil, water and
steam. | | |
1. |
Dowel pin of crankshaft should be positioned
at 3° in relation to vertical center line.

|
2. |
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.

|
3. |
Install the new O-rings (A).

|
4. |
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)
|

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. | |
5. |
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)
|

|
6. |
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)
|

Recheck the top dead center (TDC) marks
on the crankshaft and
camshaft. | |
7. |
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.)
|

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)
|

After the installation, do not
crank engine or apply pressure on the cover for half an
hour. | | |
8. |
Using the SST(09455-21200), reassemble the
timing chain cover oil seal.

|
9. |
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)
|

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.

|
•
|
Install the SST (09231-3D100) to
hold the ring gear after removing the dust
cover. |
1. |
Remove the bracket
(A).

|
2. |
Remove the dust cover (A) and
unfasten the transaxle mounting bolt (B).

|
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.

|
5. |
Tighten the bolts and nuts of the
holder and links securely.

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

|
10. |
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)
|

|
11. |
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)
|

Tighten the bolts
diagonally. | |
12. |
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)
| |
13. |
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)
|

|
14. |
Install the engine mounting support bracket
(B) and then connect the ground line (A).
Tightening
torque
Ground line bolt :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~
10.1 lb-ft)
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)
|

|
15. |
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)
|

|
16. |
Install the drive belt (A).

|
17. |
Adjust tension by tightening the alternator
tension adjust bolt (A).(Refer to Charging system in EE
Group).
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)
|

|
18. |
Before installing the cylinder head cover,
remove oil, dust or hardened sealant from the timing chain cover and
the cylinder head upper surface. |
19. |
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.)
|

|
20. |
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)
|
.gif)
•
|
Keep the OCV adapter
clean. |
•
|
Make sure the O-rings on the front
bearing cap are
installed. | | |
21. |
Install the cylinder head cover (A) with a new
gasket (B).

Do not reuse the disassembled
gasket. | |
22. |
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)
|

|
23. |
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)
|
.gif)
|
24. |
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)
|

|
25. |
Install the high pressure fuel pump (A) and
the roller tappet (B). (Refer to FL group)
Tightening
torque :
12.7 ~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~
10.8lb-ft)
|

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.
|
Do not use already used bolt again.
|
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. |
Note that internal damage may occur when
the component is dropped. In this case, use it after
inspecting. |
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. |

|
26. |
Install the high pressure pipe (A). (Refer to
FL group)
Tightening
torque :
25.5 ~ 31.4N.m (2.6 ~ 3.2kgf.m, 18.8 ~
23.1lb-ft)
|

Do not reuse the high pressure pipe.
| |
27. |
Install the vacuum pipe assembly
(A).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
28. |
Connect the fuel hose (A) and the PCSV (Purge
control solenoid valve) hose (B).

|
29. |
Connect the oxygen sensor connectors (A) and
the condenser connector (B).

|
30. |
Connect the FPCV (Fuel pressure control valve)
connector (A), the intake CMPS (Camshaft position sensor) connector
(B) and the exhaust CMPS (Camshaft position sensor) connector
(C).

|
31. |
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).

|
32. |
Connect the intake OCV (Oil control valve)
connector (A) and the exhaust OCV (Oil control valve) connector
(B).

|
33. |
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)
|

|
34. |
Install the under covers (A).
Tightening
torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~
8.0 lb-ft)
|

|
35. |
Install the RH front wheel.
|
36. |
Install the air cleaner assembly.
(1) |
Install the air cleaner assembly (D) and
then 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) .

|
•
|
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.
| |

|
37. |
Connect the battery negative terminal
(A).
Tightening
torque :
Without battery sensor :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~
7.2lb-ft)
With battery sensor :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~
4.4lb-ft)
|

|
38. |
Install the engine cover.
Make sure the engine cover is installed
before
driving. | | |