Repair Procedures: Installation

1. Using a gasket scraper, remove all the old packing 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, liquid sealant Loctite 5900H or equivalent should be applied on the gap between camshaft front bearing cap, cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.

   Bead width  : 2.0 - 3.0 mm (0.08 - 0.12 in.)

   Courtesy of HYUNDAI MOTOR AMERICA

4. After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.

   The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.

   Bead width  : 2.0 - 3.0 mm (0.08 - 0.12 in.)

   Courtesy of HYUNDAI MOTOR AMERICA

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 

   M6 X 25 bolt:

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

   M8 X 28 bolt:

   18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

   Courtesy of HYUNDAI MOTOR AMERICA

   NOTE:

   • The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.

(Refer to Timing System - "FRONT OIL SEAL ")

(Refer to Lubrication System - "OIL PAN ")

(Refer to Timing System - "DRIVE BELT TENSIONER ")

1. If there is sign of leakage from inside the E-CVVT cover, replace it with a new one.
2. Check for worn connector brush.

   Specification  : Over 5 mm (0.1969 in.)

   Courtesy of HYUNDAI MOTOR AMERICA

   If measurement is below specification, replace the E-CVVT cover with a new one.

3. Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.

   Courtesy of HYUNDAI MOTOR AMERICA

4. After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.

   Courtesy of HYUNDAI MOTOR AMERICA

1. Apply engine oil on oil seal lip (A).

   Courtesy of HYUNDAI MOTOR AMERICA

   NOTE:

   • When applying oil, keep the connector brush (A) clean from foreign materials.

     Courtesy of HYUNDAI MOTOR AMERICA

2. Insert SST (09243-C2000) into the E-CVVT motor shaft.

   Courtesy of HYUNDAI MOTOR AMERICA

   NOTE:

   • Correctly mount SST onto the motor shaft.
3. Slowly push the E-CVVT cover (A) until it is flush with the timing chain cover surface.

   Courtesy of HYUNDAI MOTOR AMERICA

   NOTE:

   • Installing the E-CVVT cover without SST may cause oil leakage inside the E-CVVT motor due to damaged or separated E-CVVT oil seal.
4. Pre-tighten the bolts in the below sequence, and then remove the SST (09243-C2000).

   Tightening torque: 

   1.0 - 2.0 N.m (0.1 - 0.2 kgf.m, 0.7 - 1.4 lb-ft)

   Fig 1: E-CVVT Cover Bolts Tightening Sequence

   Courtesy of HYUNDAI MOTOR AMERICA
5. Tighten the bolts to the specified torque in the sequence below.

   Tightening torque: 

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

   Fig 2: E-CVVT Cover Bolts Tightening Sequence

   Courtesy of HYUNDAI MOTOR AMERICA

1. By using SST (09243-C2000), insert the plug (A) into the E-CVVT cover hole.

   Courtesy of HYUNDAI MOTOR AMERICA

   NOTE:

   • Do not reuse a E-CVVT motor plug.
2. Mount the stopper of SST so that it sits at the end of E-CVVT motor shaft.

   Courtesy of HYUNDAI MOTOR AMERICA

1. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of motor shaft (1).
2. By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT plug (2).

   Courtesy of HYUNDAI MOTOR AMERICA

3. Calculate the pressed depth (3) of motor plug.

   If out of specification, reinstall after replacing the E-CVVT plug with a new one.

   Pressed depth  : (3) = (2) - (1)

   Specification  : 1.9 - 2.1 mm (0.0748 - 0.0827 in.)