Repair procedures: Installation

Install the camshaft sprocket and tighten the bolt to the specified torque.
1. Temporarily install the camshaft sprocket bolt (C).
2. Hold the portion (A) of the camshaft with a hexagonal wrench, and tighten the bolt (C) with a wrench (B).
  Tightening torque:
  
  78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
  
  Fig 1: Holding Portion Of Camshaft With Hexagonal Wrench
  Courtesy of HYUNDAI MOTOR CO.
Install the cylinder head cover.
1. Install the cylinder head cover (A) and bolts (B).
  Tightening torque:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  NOTE: Tighten the cylinder head cover bolts as following method.
  
  Fig 2: Identifying Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR CO.
2. Install the engine cover bracket (A).
  
  Fig 3: Locating Engine Cover Bracket
  Courtesy of HYUNDAI MOTOR CO.
3. Install the PCV (Positive Crankcase Ventilation) hose (A) and breather hose (B) to the cylinder head cover.
  
  Fig 4: Locating Positive Crankcase Ventilation Hose And Breather Hose
  Courtesy of HYUNDAI MOTOR CO.
4. Install the ignition coil.
  
  Fig 5: Identifying Ignition Coil
  Courtesy of HYUNDAI MOTOR CO.
Install the crankshaft sprocket (A).

Fig 6: Locating Crankshaft Sprocket
Courtesy of HYUNDAI MOTOR CO.
Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at top dead center and its compression stroke.

Fig 7: Aligning Timing Marks Of Camshaft Sprocket With No. 1 Piston Placed At Top Dead Center
Courtesy of HYUNDAI MOTOR CO.

Fig 8: Aligning Timing Marks Of Crankshaft Sprocket With No. 1 Piston Placed At Top Dead Center
Courtesy of HYUNDAI MOTOR CO.
Install the idler pulley (A) and tighten the bolt (B) to the specified torque.
Tightening torque:

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

Fig 9: Locating Idler Pulley And Bolt
Courtesy of HYUNDAI MOTOR CO.
Temporarily install the timing belt tensioner (A).

Fig 10: Locating Timing Belt Tensioner
Courtesy of HYUNDAI MOTOR CO.
Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt. Crankshaft sprocket (A) → idler pulley (B) → camshaft sprocket (C) → timing belt tensioner (D).

Fig 11: Locating Crankshaft Sprocket, Idler Pulley, Camshaft Sprocket And Timing Belt Tensioner
Courtesy of HYUNDAI MOTOR CO.

Adjust the timing belt tension.

Loosen the tensioner pulley mounting bolt and apply tension to the timing belt.

Fig 12: Applying Tension To Timing Belt
Courtesy of HYUNDAI MOTOR CO.
After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt (A) and (B) one by one.
Tightening torque:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
Then recheck the belt tension.
Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49 N (11 lb)], the timing belt cog end is approx. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center.

Fig 13: Checking Belt Tension
Courtesy of HYUNDAI MOTOR CO.

Timing belt tension measuring procedure [Using a mechanical tension gauge (BT-33-73F, BTG-2 type)]

Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90° then measure the belt tension in the middle of tension side span (in both arrow direction of above illustration) by free vibration method.

CAUTION: When rotating the crankshaft counter-clockwise, be sure to rotate the crankshaft at a time.

Input the belt specifications into the tension meter.

BELT SPECIFICATIONS

Location of measurement		Input data
Location of measurement		M (Mass, g/m.mm)	W (Width, mm)	S (Span, mm)
T1	Camshaft sprocket to crankshaft sprocket	4.5	22	250
T2	Camshaft sprocket to tensioner	4.5	22	231

Locate the micro phone close to the center of belt span (T1, T2) and bounce the belt by finger 2~3 times. Read a value on the display.

Fig 14: Locating Micro Phone Close To Center Of Belt Span (T1, T2)
Courtesy of HYUNDAI MOTOR CO.
Measure both T1 and T2 at the A and B points respectively and then calculate the average

Fig 15: Belt Tension Calculation Formula
Courtesy of HYUNDAI MOTOR CO.

Average Belt Tension (T)

Without CVVT (1.4 L/1.6 L): 20 ± 3.5 kgf

With CVVT (1.6 L): 18 ± 3.5 kgf

Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.
Install the timing belt lower cover (A) with 5 bolts (B).
Tightening torque:

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

Fig 16: Locating Timing Belt Lower Cover And Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the flange and crankshaft pulley (A), and then tighten crankshaft pulley bolt.
Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque:

137.3 ~ 147.1 N.m (14.0 ~ 15.0 kgf.m, 101.3 ~ 108.5 lb-ft)

Fig 17: Locating Crankshaft Pulley And Bolt
Courtesy of HYUNDAI MOTOR CO.
Install the timing belt upper cover (A) with 4 bolts (B).
Tightening torque:

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

Fig 18: Locating Timing Belt Upper Cover And Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the water pump pulley and 4 bolts.
Install the power steering pump drive belt (C). (Refer to POWER STEERING PUMP ).

Fig 19: Engine Drive Belt Routing
Courtesy of HYUNDAI MOTOR CO.
Install the air conditioner compressor drive belt (B).
(Refer to AIR CONDITIONING SYSTEM ).
Install the alternator drive belt (A). (Refer to ALTERNATOR ).
Install the RH side cover (A) with 2 bolts (B).

Fig 20: Locating RH Side Cover And Bolts
Courtesy of HYUNDAI MOTOR CO.
Install the RH front wheel.
Tightening torque:

88.3 ~ 98.1 N.m (9.0 ~ 10.0 kgf.m, 65.1 ~ 72.3 lb-ft)
Install the engine cover with bolts.
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)