Repair procedures: Removal

Engine removal is not required for this procedure.

1. Disconnect the battery negative terminal.

   (Refer to ENGINE AND TRANSAXLE ASSEMBLY )

2. Remove the RH front wheel.

   (Refer to "WHEEL ")

3. Remove the RH under cover.

   (Refer to ENGINE AND TRANSAXLE ASSEMBLY )

4. Remove the engine cover.

   (Refer to ENGINE AND TRANSAXLE ASSEMBLY )

5. Disconnect the wiring connectors and harness clamps, and then remove the wiring and protectors from the cylinder head cover.
   1. The intake OCV (Oil control valve) connector (A)
      Fig 1: Intake OCV (Oil Control Valve) Connector

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   2. The exhaust OCV (Oil control valve) connector (A)
      Fig 2: Exhaust OCV (Oil Control Valve) Connector

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   3. The alternator connector (A)
      Fig 3: Alternator Connector

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   4. The ignition coil connectors (A)
      Fig 4: Identifying Ignition Coil Connectors

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   5. The intake CMPS (Camshaft position sensor) connector (A)
   6. The exhaust CMPS (Camshaft position sensor) connector (B)
      Fig 5: Intake And Exhaust CMPS (Camshaft Position Sensor) Connector

      Courtesy of HYUNDAI MOTOR AMERICA
6. Disconnect the breather hose (A).
   Fig 6: Breather Hose

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7. Disconnect the PCV (Positive crankcase ventilation) hose (A).
   Fig 7: PCV (Positive Crankcase Ventilation) Hose

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8. Remove the ignition coils (A).
   Fig 8: Ignition Coils

   Courtesy of HYUNDAI MOTOR AMERICA
9. Remove the engine oil level gauge (A).
   Fig 9: Engine Oil Level Gauge

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10. Remove the cylinder head cover (A).
    Fig 10: Cylinder Head Cover

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    NOTE: Unfasten the bolts in the sequence as shown below.
    Fig 11: Cylinder Head Cover Bolts Loosening Sequence

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11. Drain engine oil and remove the oil pan.

    (Refer to ENGINE LUBRICATION SYSTEM )

12. Remove the engine mounting support bracket.
    1. Set the jack to the edge of the lower crankcase.
       NOTE: Put the wooden block between lower crankcase and jack.
       CAUTION: Be careful not to damage the oil screen.
    2. Disconnect the engine ground line (A).
    3. Remove the engine mounting support bracket (B).
       Fig 12: Engine Mounting Support Bracket And Engine Ground Line

       Courtesy of HYUNDAI MOTOR AMERICA
13. Remove the drive belt.
    1. Loosen the alternator mounting bolts (A).
    2. Loosen the tension by turning the tension adjusting bolt (B) counterclockwise.
    3. Remove the drive belt (C).
       Fig 13: Drive Belt, Tension Adjusting Bolt And Alternator Mounting Bolts

       Courtesy of HYUNDAI MOTOR AMERICA
14. Remove the front engine hanger (A).
    Fig 14: Front Engine Hanger

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15. Remove the alternator (A).

    (Refer to "ALTERNATOR ")

    Fig 15: Alternator And Bolts

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16. Remove the water pump pulley (A).
    Fig 16: Water Pump Pulley

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17. Set No. 1 cylinder to TDC (Top dead center) on compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
       Fig 17: Aligning Groove With Timing Mark Of Timing Chain Cover

       Courtesy of HYUNDAI MOTOR AMERICA
    2. Check that the TDC marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration below. If not, turn the crankshaft by one revolution (360°) more.
       Fig 18: Intake And Exhaust CVVT Sprockets TDC Marks

       Courtesy of HYUNDAI MOTOR AMERICA
       NOTE: Do not turn the crankshaft pulley counterclockwise.
18. Remove the crankshaft damper pulley (A).
    Fig 19: Identifying Crankshaft Damper Pulley

    Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION: Do not press the pulley or apply the excessive force to prevent the rubber part from being deformed.
    NOTE: There are two methods to hold the ring gear when removing the crankshaft damper pulley.

    • Install the SST (09231-2B100) to hold the ring gear after removing the starter.
      Fig 20: Holding Ring Gear Using SST (09231-2B100)

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

    1. Remove the air guard (A).
       Fig 21: Air Guard

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    2. Remove the two transaxle mounting bolts (A) and the service cover (B) on the bottom of the lower crankcase.
       Fig 22: Transaxle Mounting Bolts And Service Cover

       Courtesy of HYUNDAI MOTOR AMERICA
    3. Adjust the length of the holder (A) so that the grooves of the holder puts into the ring gears (B) at the closest position.
    4. Adjust the angle and length of the links (C) so that the two transaxle mounting bolts can be fastened into the original mounted holes.
       Fig 23: Holder, Ring Gear And Link

       Courtesy of HYUNDAI MOTOR AMERICA
    5. Install the SST using the two transaxle mounting bolts. Tighten the bolts and nuts of the holder and links securely.
       Fig 24: Installing SST Using Transaxle Mounting Bolts

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19. Remove the timing chain cover (A) by gently prying the gaps between the cylinder head and cylinder block.
    Fig 25: Timing Chain Cover With Bolts

    Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
20. Remove the timing chain tensioner (A).
    Fig 26: Timing Chain Tensioner

    Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION:

    • Do not reuse the detached tensioner.
    • If need to reuse the tensioner, remove the tensioner, make the piston (A) to protrude maximally, push the piston (A) to the end, and then mount the stopper pin.

      At this time, the tensioner fixing pin should be placed in the same way as when the product was first delivered from the factory.

    Fig 27: Piston protruding maximally

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    Fig 28: Piston Compressed

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21. Remove the timing chain tensioner arm (A).
    Fig 29: Timing Chain Tensioner Arm

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22. Remove the timing chain (A).
    Fig 30: Timing Chain

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23. Remove the timing chain guide (A).
    Fig 31: Timing Chain Guide

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