Repair Procedures: Installation

The TDC marks of the intake and exhaust CVVT sprockets are slightly turned from the TDC position as shown in illustration when the timing chain is removed.

Fig 1: Identifying TDC Marks Of Intake And Exhaust CVVT Sprockets
Courtesy of HYUNDAI MOTOR AMERICA
Turn the crankshaft clockwise (about 2~3 pitches) from the TDC position (the dowel pin (A) of crankshaft is about 3° with the engine vertical line) as rotation of the intake CVVT sprocket from the TDC position.

Fig 2: Turning Crankshaft Clockwise (About 2~3 Pitches) From TDC Position
Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain guide (A).
Tightening torque: 18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 3: Removing/Installing Timing Chain Guide
Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain tensioner arm (A).
Tightening torque: 18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft

Fig 4: Removing/Installing Timing Chain Tensioner Arm
Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain.
Crankshaft sprocket (A) Timing chain guide (B) Intake CVVT sprocket (C) Exhaust CVVT sprocket (D)
1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
  
  Fig 5: Installing Timing Chain
  Courtesy of HYUNDAI MOTOR AMERICA
  
  NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.
2. Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.
  
  Fig 6: Turning CVVT Assembly Clockwise
  Courtesy of HYUNDAI MOTOR AMERICA
  NOTE:
  - The timing mark of the exhaust CVVT sprocket should be matched with timing mark (color link) of timing chain when installing the timing chain.
  - Press down the timing chain links on the exhaust CVVT sprocket to prevent the sprocket from spinning.
Install the timing chain auto tensioner (A) and remove the stopper pin (B).
Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 7: Installing Timing Chain Auto Tensioner & Removing Stopper Pin
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- When reinstalling the tensioner, check the ratchet function of the tensioner after removing the fixing pin by retracting the tensioner arm (A) maximally as shown in illustration below.
- When maximally retracted, there should be no interference between the tensioner arm (A) and tensioner housing (B).
  
  Fig 8: Retracting Tensioner Arm At Tensioner Housing
  Courtesy of HYUNDAI MOTOR AMERICA
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks on the intake and exhaust CVVT sprockets are aligned with the top surface of cylinder head.

Fig 9: Identifying TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of HYUNDAI MOTOR AMERICA
Install the timing chain cover.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
3. Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.
  Bead width: 3.0 ~ 5.0 mm (0.11 ~ 0.20 in.)
  
  Sealant: Threebond 1217H or equivalent
  
  Fig 10: Chain Cover And Counter Parts Sealant Locations
  Courtesy of HYUNDAI MOTOR AMERICA
4. After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path from oil leakage.
  Bead width
  
  Whole section: 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)
  
  Section A: 4.5 ~ 5.5 mm (0.18 ~ 0.22 in.)
  
  Section B: 8.0 ~ 9.0 mm (0.32 ~ 0.35 in.)
  
  Sealant: Threebond 1217H or equivalent
  
  Fig 11: Applying Liquid Sealant On Timing Chain Cover
  Courtesy of HYUNDAI MOTOR AMERICA
5. Install the timing chain cover. 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 in exact position.
  Tightening torque
  
  Bolts (A, B):
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  Bolt (C):
  
  19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)
  
  Bolts (D, E):
  
  39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)
  
  Bolt (F):
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 12: Identifying Timing Chain Cover Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Do not reuse the seal bolts (C, F).
  
  CAUTION: The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.
Replace the front oil seal if necessary.
1. Apply engine oil on the edge of new oil seal.
  CAUTION: Remove any debris from the lip portion of the oil seal.
2. Install the front oil seal using SST (09231-2E000).
  
  Fig 13: Installing Front Oil Seal Using SST (09231-2E000)
  Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft damper pulley (A).
Tightening torque: 196.1 ~ 205.9 N.m (20.0 ~ 21.0 kgf.m, 144.7 ~ 151.9 lb-ft)

Fig 14: Removing/Installing 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 installing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 15: Installing SST (09231-2B100) To Hold Ring Gear
  Courtesy of HYUNDAI MOTOR AMERICA
- Install the SST (09231-3D100) to hold the ring gear after removing the service cover.
1. Remove the air guard (A).
  
  Fig 16: Identifying Air Guard
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the two transaxle mounting bolts (A) and the service cover (B) on the bottom of the lower crankcase.
  
  Fig 17: Removing Transaxle Mounting Bolts & 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 18: Adjusting Length Of Holder So Grooves Of Holder Fits Into Ring Gears
  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 19: Installing SST Using Transaxle Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
Install the water pump pulley (A).
Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 20: Removing/Installing Water Pump Pulley
Courtesy of HYUNDAI MOTOR AMERICA
Install the front engine hanger (A).
Tightening torque: 34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)

Fig 21: Removing/Installing Front Engine Hanger
Courtesy of HYUNDAI MOTOR AMERICA
Install the drive belt.
1. Preassemble the alternator (A) temporarily.
  
  Fig 22: Identifying Alternator
  Courtesy of HYUNDAI MOTOR AMERICA
2. Install the drive belt (B).
3. Adjust the tension by turning the tension adjusting bolt (A) clockwise. (Refer to "ALTERNATOR ")
  Belt tension
  
  New belt:
  
  637.4 ~ 735.5 N (65 ~ 75 kgf, 143.3 ~ 165.3 lbf)
  
  Used belt:
  
  441.3 ~ 539.4 N (45 ~ 55 kgf, 99.2 ~ 121.3 lbf)
  
  Fig 23: Alternator Mounting Bolts & Drive Belt Routing Diagram
  Courtesy of HYUNDAI MOTOR AMERICA
4. Tighten the alternator mounting bolts with the specified torque.
  Tightening torque
  
  M10 bolt:
  
  29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
  
  M8 bolt:
  
  21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)
Install the engine mounting support bracket.
1. Install the engine mounting support bracket (B).
  Tightening torque
  
  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)
2. Connect the engine ground line (A).
  
  Fig 24: Identifying Engine Mounting Support Bracket & Ground Line
  Courtesy of HYUNDAI MOTOR AMERICA
3. Remove the jack from the lower crankcase.
Install the oil pan. (Refer to LUBRICATION SYSTEM - 1.8L )
Install cylinder head cover.
1. The hardening sealant located on the cylinder head cover and the gap between the timing chain cover and the cam carrier should be removed before assembling cylinder head cover.
2. Apply engine oil on the lip portion of the oil seal on the cover and outer surface of the spark plug pipes.
3. After applying sealant on the gap between the timing chain cover and the cam carrier, it should be assembled within 5 minutes.
  Bead width: 2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)
  
  Sealant: Threebond 1217H or equivalent
  
  Fig 25: Applying Sealant On Area On Gap Between Timing Chain Cover And Cam Carrier
  Courtesy of HYUNDAI MOTOR AMERICA
4. Install the cylinder head cover (A) by tightening the bolts, in several passes, in the sequence as shown in illustration.
  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)
  
  Fig 26: Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  CAUTION:
  - Do not reuse cylinder head cover gasket.
  - Before installing the cylinder head cover, make sure the cylinder head cover gasket is not separated from the cylinder head cover gasket groove.
  - The engine running or pressure test should not be performed within 30 minutes after the cylinder head cover was assembled.
Install the oil level gauge (A).

Fig 27: Removing/Installing Engine Oil Level Gauge
Courtesy of HYUNDAI MOTOR AMERICA
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)

Fig 28: Removing/Installing Ignition Coils
Courtesy of HYUNDAI MOTOR AMERICA
Connect the PCV (Positive Crankcase Ventilation) hose (A).

Fig 29: Identifying PCV (Positive Crankcase Ventilation) Hose
Courtesy of HYUNDAI MOTOR AMERICA
Connect the breather hose (A).

Fig 30: Identifying Breather Hose
Courtesy of HYUNDAI MOTOR AMERICA
Install the wiring and protectors on the cylinder head cover and then connect the wiring connectors and harness clamps.
1. The intake OCV (Oil Control Valve) connector (A)
  
  Fig 31: Identifying Intake OCV (Oil Control Valve) Connector
  Courtesy of HYUNDAI MOTOR AMERICA
2. The exhaust OCV (Oil Control Valve) connector (A)
  
  Fig 32: Identifying Exhaust OCV (Oil Control Valve) Connector
  Courtesy of HYUNDAI MOTOR AMERICA
3. The alternator connector (A)
  
  Fig 33: Identifying Alternator Connector
  Courtesy of HYUNDAI MOTOR AMERICA
4. The ignition coil connectors (A)
  
  Fig 34: Identifying Ignition Coil Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
5. The intake CMPS (Camshaft position sensor) connector (A)
6. The exhaust CMPS (Camshaft position sensor) connector (B)
  
  Fig 35: Identifying Intake/Exhaust CMPS (Camshaft Position Sensor) Connectors
  Courtesy of HYUNDAI MOTOR AMERICA
Install the engine cover. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the RH under cover. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the RH front wheel. (Refer to "WHEEL ")
Connect the battery negative terminal. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
NOTE:
- Refill engine with engine oil.
- Clean battery posts and cable terminals and assemble.
- Inspect for fuel leakage.
  - After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.