How to time the cam and crank on Hyundai accent 1.6L DOHC 2004?

TIMING BELT:----

General Information

Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:

Does the owner know if, or when the belt was replaced-

If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt.

Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).

Interference Engines

Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Inspection

NOTE

For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.

WARNING

Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.

Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:

Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail

Cracks on the rubber backing

Cracks or peeling of the canvas backing

Cracks on rib root

Cracks on belt sides

Missing teeth or chunks of teeth

Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.

WARNING

On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.

Fig. Broken tooth may be due to a damaged pulley

Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover

Fig. Side wear from improper installation

Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

Removal & Installation

NOTE

The radio may have a coded theft protection circuit. Obtain the code before disconnecting the battery, removing the radio fuse, or removing the radio.

CAUTION

Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.

CAUTION

On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

1.5L And 1.6L Engines

1. Remove all necessary components for access to the timing belt cover, then remove the cover.
2. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
3. Loosen the tensioning bolt and the pivot bolt on the timing belt tensioner. Move the tensioner as far as it will go toward the water pump. Tighten the adjusting bolt.
4. Mark the timing belt with an arrow showing direction of rotation.
5. Remove the timing belt.
6. If defective, remove the timing belt tensioner.

To install:

Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L DOHC engines

Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines

1. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
2. If removed, install the timing belt tensioner, spring and spacer with the bottom end of the spring free. Tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump.
3. Install the free end of the spring into the locating tang on the front case.
4. Position the timing belt over the crankshaft sprocket, then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
5. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and be sure the timing marks align.
   
   NOTE

   If the timing marks are not properly aligned, shift the belt 1 tooth at a time in the appropriate direction until they are aligned.
   
   
6. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Be sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around. Correct the path of the belt, if necessary.
7. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
   
   NOTE

   Bolts must be tightened in the stated order or tension won't be correct.
   
   
8. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
9. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
10. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are approximately ¹ / ₂ of the way across the head of the tensioner adjusting bolt. Re-tension the belt, if necessary.
11. Install the timing belt covers and all other related components.

1.5L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Water pump pulley bolts

   Alternator bolt, loosen only

   Water pump pulley and drive belts

   Crankshaft pulley

   Timing belt cover
   
   
3. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
4. Loosen the tensioning bolt and the pivot bolt on the timing belt tensioner. Move the tensioner as far as it will go toward the water pump. Tighten the adjusting bolt.
5. Mark the timing belt with an arrow showing direction of rotation.
6. Move the timing belt tensioner pulley toward the water pump and temporarily secure it.
7. Remove or disconnect the following:
   
   
   Timing belt

   Crankshaft sprocket bolts, sprocket and flange

   Timing belt tensioner, if defective
   
   

To install:

Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L DOHC engines

Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines

1. Install the flange and crankshaft sprocket. Tighten the crankshaft sprocket bolt to 103-111 ft. lbs. (140-150 Nm).
2. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
3. If removed, install the timing belt tensioner, spring and spacer with the bottom end of the spring free. Tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump.
4. Install the free end of the spring into the locating tang on the front case.
5. Position the timing belt over the crankshaft sprocket, then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
6. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and be sure the timing marks align.

NOTE

If the timing marks are not properly aligned, shift the belt 1 tooth at a time in the appropriate direction until they are aligned.

1. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Be sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around. Correct the path of the belt, if necessary.
2. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).

NOTE

Bolts must be tightened in the stated order or tension won't be correct.

1. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
2. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
3. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are approximately¹₂
4. Install or connect the following:
   
   
   Timing belt cover

   Crankshaft pulley

   A/C compressor belt

   Water pump pulley

   V belt

   Negative battery cable

   Engine with coolant
   
   

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Water pump pulley bolts

   Alternator bolt, loosen only

   Water pump pulley and drive belts

   Crankshaft pulley

   Timing belt cover
   
   
3. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
4. Loosen the tensioning bolt and the pivot bolt on the timing belt tensioner. Move the tensioner as far as it will go toward the water pump. Tighten the adjusting bolt.
5. Mark the timing belt with an arrow showing direction of rotation.
6. Move the timing belt tensioner pulley toward the water pump and temporarily secure it.
7. Remove or disconnect the following:
   
   
   Timing belt

   Crankshaft sprocket bolts, sprocket and flange

   Timing belt tensioner, if defective
   
   

To install:

Fig. Proper pulley alignment for timing belt installation at TDC-Hyundai 1.5L SOHC engines, 1.6L similar

1. Install the flange and crankshaft sprocket. Tighten the crankshaft sprocket bolt to 103-111 ft. lbs. (140-150 Nm).
2. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
3. If removed, install the timing belt tensioner, spring and spacer with the bottom end of the spring free. Tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump.
4. Install the free end of the spring into the locating tang on the front case.
5. Position the timing belt over the crankshaft sprocket, then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
6. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and be sure the timing marks align.
   
   NOTE

   If the timing marks are not properly aligned, shift the belt 1 tooth at a time in the appropriate direction until they are aligned.
   
   
7. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Be sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around. Correct the path of the belt, if necessary.
8. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
   
   NOTE

   Bolts must be tightened in the stated order or tension won't be correct.
   
   
9. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
10. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
11. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are approximately ¹ / ₂ of the way across the head of the tensioner adjusting bolt. Re-tension the belt, if necessary.
12. Install or connect the following:
    
    
    Timing belt cover

    Crankshaft pulley

    A/C compressor belt

    Water pump pulley

    V belt

    Negative battery cable

    Engine with coolant
    
    

1.8L (VIN M) And 2.0L (VIN F) Engines

1. Remove all necessary components for access to the timing belt cover, then remove the cover.
2. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
3. Remove the timing belt tensioner and idler pulley.
4. Mark the timing belt with an arrow showing direction of rotation.
5. Remove the timing belt.
   
   
   

   

   Fig. Proper alignment of the timing belt alignment marks for belt removal and installation-Hyundai 1.8L and 2.0L (VIN F) engines

To install:

1. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
2. Install the timing belt tensioner.
3. Install the idler pulley, if equipped. Tighten bolt to 32-41 ft. lbs. (43-55 Nm).
4. Position the timing belt over the camshaft sprocket, then over the crankshaft sprocket.
5. Tension the timing belt and tighten the tensioner pulley bolt to 32-41 ft. lbs. (43-55 Nm). When properly tensioned, the timing belt should deflect 0.16-0.24 in. (4-6mm) when a force of 5 lbs. (2.2kg) is placed on the longest span of the belt.
6. Turn the crankshaft sprocket one turn clockwise and realign the crankshaft sprocket timing mark.
7. Recheck the belt tension and adjust as necessary.
8. Install the timing belt cover and all other applicable components.

2.0L (VIN P) Engines

1. Remove all necessary components for access to the timing belt covers, then remove the covers.
   
   NOTE

   Always rotate the crankshaft in a clockwise direction.
   
   
2. Rotate the crankshaft clockwise and align the timing marks so the No. 1 piston will be at Top Dead Center (TDC) of the compression stroke. At this time the timing marks on the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the camshaft sprocket should be at the upper side.
3. Remove the outer timing belt tensioner.
4. Mark the timing belts, indicating the direction of rotation.
5. Remove the outer timing belt.
6. Remove the camshaft sprockets.
7. Insert a prytool with a 0.32 in. (8mm) diameter shaft into the left side cylinder block plug hole. The prytool will hold the counterbalance shaft stable while removing the oil pump sprocket retaining nut.
8. Remove the oil pump sprocket.
9. Loosen the right counterbalance shaft sprocket bolt.
10. Remove the inner timing belt tensioner.
11. Remove the inner timing belt.
    
    
    

    

    Fig. Oil pump and crankshaft inner timing belt sprocket alignment marks-Hyundai 2.0L (VIN P) engines

    
    
    
    

    

    Fig. Timing belt sprocket alignment mark locations and positioning for belt removal and installation-Hyundai 2.0L (VIN P) engines

To install:

1. Install the counterbalance shaft sprocket and tighten the flange bolt finger-tight.
2. Align the timing mark on each sprocket with the corresponding timing mark on the front case.
3. Install the inner timing belt.
   
   NOTE

   When installing the inner timing belt, ensure that the tension side has no slack.
   
   
4. Install the inner timing belt tensioner with the center of the pulley on the left side of the mounting bolt and with the pulley flange facing the front of the engine.
5. Lift the inner timing belt tensioner to tighten the inner timing belt so that its tension side will be pulled tight.
6. Tighten the bolt to secure the inner tensioner.
   
   NOTE

   When tightening the bolt of the tensioner, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.
   
   
7. Ensure the timing marks are in alignment.
8. Check the belt for proper tension by depressing the belt on its long side with your finger and noting the belt deflection. The desired deflection should be 0.20-0.28 in. (5-7mm).
9. Install the flange, crankshaft sprocket and washer on the crankshaft. The flange on the crankshaft sprocket must be installed towards the inner timing belt sprocket. Tighten the bolt to 80-94 ft. lbs. (110-130 Nm).
10. Insert a prytool with a 0.32 in. (8mm) diameter shaft into the left side cylinder block plug hole. The prytool will hold the counterbalance shaft stable while removing the oil pump sprocket retaining nut.
11. Install the oil pump sprocket and tighten the nut to 36-43 ft. lbs. (50-60 Nm).
12. Install the camshaft sprocket and tighten the bolt to 56-72 ft. lbs. (80-100 Nm).
13. Carefully push the auto-tensioner rod in until the set hole in the rod is aligned with the hole in the cylinder. Place a wire into the hole to retain the rod.
14. Install the outer timing belt tensioner.
15. Install the outer tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Tighten the center bolt finger-tight.
16. Turn the two camshaft sprockets so their dowel pins are located on top. Align the timing marks facing each other with the top surface of the cylinder head.
    
    NOTE

    Both camshaft sprockets are used for the intake and exhaust camshafts and are provided with two timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the mark on the left with the dowel pin hole on top.
    
    
17. Align the crankshaft sprocket and oil pump sprocket timing marks.
18. Insert a prytool with a 0.32 in. (8mm) diameter shaft into the left side cylinder block plug hole. If the shaft can be inserted 2.4 in. (61mm), the silent shaft is in the correct position. If the shaft of the tool can only be inserted 0.8-1.0 in. (20-25mm) deep, turn the oil pump sprocket one full turn and realign the marks.
    
    NOTE

    Keep the tool inserted in hole for the remainder of this procedure. The above step assures that the oil pump socket is in correct orientation to the silent shafts. This step must not be skipped or a vibration may develop during engine operation.
    
    
19. Install the timing belt around the tensioner pulley and crankshaft sprocket. Hold the belt with your left-hand.
20. Pulling the belt with your right-hand, install it around the oil pump sprocket.
21. Install the belt around the idler pulley and intake camshaft sprocket.
22. Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top surface. Pulling the belt with both hands, install it around the exhaust camshaft sprocket.
23. Gently raise the tensioner pulley so that the belt does not sag and temporarily tighten the center bolt.
24. Turn the crankshaft ¹ / ₄ turn counterclockwise. Turn the crankshaft clockwise to move the No. 1 cylinder to TDC.
25. Loosen the center bolt and attach special tool PN 09244-28100 to a torque wrench. Apply a torque of 23-25 inch lbs. (2.6-2.8 Nm). Tighten the center bolt.
26. Screw the special tool PN 09244-28000 into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto-tensioner, if the wire was not previously removed. Remove the special tool.
27. Rotate the crankshaft 2 complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto-tensioner protrusion (the distance between the tensioner arm and auto-tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm).
28. If the timing belt tension adjustment is being performed with the engine mounted in the vehicle, and clearance between the tensioner arm and the auto-tensioner body cannot be measured, the following alternative method can be used:
    1. Screw in special tool PN 09244-28000 until its end makes contact with the tensioner arm.
    2. After the tool makes contact with the arm, screw it in some more to retract the auto-tensioner pushrod while counting the number of turns the tool makes until the tensioner arm is brought into contact with the auto-tensioner body. Be sure the number of turns the special tool makes conforms with the standard value of 2 ¹ / ₂-3 turns.
    3. Install the rubber plug to the timing belt rear cover.

    
    
29. Install the timing belt covers.

3.0L (VIN G)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine cover
   
   
3. Rotate the drive belt tensioner clockwise approximately 14 degrees and remove the belt from the pulley.
   
   
   Power steering pump pulley

   Idler pulley

   Tensioner pulley

   Crankshaft pulley

   Upper and lower timing belt covers

   Auto tensioner
   
   
4. Rotate the crankshaft clockwise and align the timing mark to set the No. 1 cylinder piston at Top Dead Center (TDC).
5. Remove the timing belt.

To install:

Fig. Installation of the timing belt-3.0L (VIN G) engine

1. Install or connect the following:
   
   
   Idler pulley to the engine support lower bracket

   Tensioner arm, shaft and plane washer to the engine and torque the bolts to 40 ft. lbs. (55 Nm)

   Crankshaft sprocket and align the timing marks

   Auto tensioner to the oil pump case
   
   
2. Align the timing marks on each sprocket and install the timing belt as follows:
   
   
   Crankshaft sprocket

   Idler pulley

   Exhaust camshaft sprocket (left side)

   Intake camshaft sprocket (left side)

   Water pump pulley

   Intake camshaft sprocket (right side)

   Exhaust camshaft sprocket (right side)

   Tensioner pulley
   
   
3. Verify the timing marks are properly set.
4. Install or connect the following:
   
   
   Tensioner pulley and remove the set pin from the auto tensioner

   Negative battery cable
   
   

3.0L Engine

1. Remove all necessary components for access to the timing belt covers, then remove the covers.
2. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
3. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
4. Mark the timing belt with an arrow showing direction of rotation.
5. Remove the timing belt.
6. If defective, remove the timing belt tensioner.
   
   
   

   

   Fig. Timing belt sprocket alignment mark positioning for belt removal and installation-Hyundai 3.0L engine

To install:

1. If necessary, install the timing belt tensioner.
2. Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine
3. Rotate the timing belt tensioner to the extreme counterclockwise position. Temporarily lock the tensioner in place.
4. Align the timing marks of the camshaft and crankshaft sprockets.
5. Install the timing belt on the crankshaft sprocket, then onto the rear camshaft sprocket.
6. Route the belt to the coolant pump pulley, the front camshaft sprocket and the timing belt tensioner.
7. Apply force counterclockwise to the rear camshaft sprocket with tension on the tight side of the belt and check that timing marks are aligned.
8. Loosen the tensioner bolt 1-2 turns and tighten the timing belt to a tension of 57-84 lbs. (260-380 N).
9. Turn the crankshaft two turns clockwise.
10. Readjust the sprocket timing marks and tighten the tensioner bolts.
11. Install the timing belt covers.
12. Install the crankshaft pulley and tighten to 108-116 ft. lbs. (150-160 Nm).
13. Install all applicable components.

3.5L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Before servicing the vehicle, refer to the Precautions Section.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Water pump pulley bolts

   Alternator bolt, loosen only

   Water pump pulley and drive belts

   Crankshaft pulley

   Timing belt cover(s)
   
   
4. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
5. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
6. Mark the timing belt with an arrow showing direction of rotation.
7. Remove the timing belt.
8. If defective, remove the timing belt tensioner.
   
   
   

   

   Fig. Timing belt sprocket alignment mark positioning for belt removal and installation-3.5L engine

To install:

1. If necessary, install the timing belt tensioner.
2. Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine
3. Rotate the timing belt tensioner to the extreme counterclockwise position. Temporarily lock the tensioner in place.
4. Align the timing marks of the camshaft and crankshaft sprockets.
5. Install the timing belt on the crankshaft sprocket, then onto the rear camshaft sprocket.
6. Route the belt to the coolant pump pulley, the front camshaft sprocket and the timing belt tensioner.
7. Apply force counterclockwise to the rear camshaft sprocket with tension on the tight side of the belt and check that timing marks are aligned.
8. Loosen the tensioner bolt 1-2 turns and tighten the timing belt to a tension of 57-84 lbs. (260-380 N).
9. Turn the crankshaft two turns clockwise.
10. Readjust the sprocket timing marks and tighten the tensioner bolts.
11. Install the timing belt covers.
12. Install the crankshaft pulley and tighten to 108-116 ft. lbs. (150-160 Nm).
13. Install or connect the following:
    
    
    Timing belt cover(s)

    Crankshaft pulley

    A/C compressor belt

    Water pump pulley

    V belt

    Negative battery cable

    Engine with coolant

Timing belt sprockets:---------

Removal & Installation

CAUTION

Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.

1.6L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Engine support bracket

   Accessory drive belts

   Water pump pulley

   Crankshaft pulley

   Timing belt cover
   
   
3. Move the timing belt tensioner pulley toward the water pump and secure it.
4. Remove the timing belt.

To install:

1. Install the timing belt and turn the crankshaft sprocket in a reverse direction and align the timing marks.
2. Turn the crankshaft two turns in its operating direction and realign the camshaft sprocket timing mark to Top Dead Center (TDC).
3. Install or connect the following:
   
   
   Timing belt cover. Tighten the bolts to 84 inch lbs. (10 Nm).

   Crankshaft pulley. Tighten to 111 ft. lbs. (150 Nm).

   Water pump pulley

   Accessory drive belts

   Engine support bracket

   Negative battery cable
   
   
4. Refill the engine with coolant to the correct level.

-------------------------------------------------------------------------------

Timing belt front cover:---

Removal & Installation

1. Remove the engine cover.
2. Remove RH front wheel.
3. Remove 2 bolts (B) and RH side cover (A).
   
   
   

   

   Fig. RH side cover location

4. Remove the engine mount bracket.
5. Set the jack to the engine oil pan.
   
   NOTE

   Place wooden block between the jack and engine oil pan.
   
   
   
   
   

   

   Fig. Jack placement

6. Remove the bolt (B), 3 nuts (C, D) and engine mount bracket (A).
   
   
   

   

   Fig. Engine mount bracket location

7. Remove the bolt (B) and stay plate (A).
   
   
   

   

   Fig. Stay plate location

8. Temporarily loosen the water pump pulley bolts.
   
   
   

   

   Fig. Water pump pulley bolts location

9. Remove alternator belt.
10. Remove air compressor belt.
11. Remove power steering belt.
12. Remove 4 bolts and water pump pulley.
13. Remove the 4 bolts and timing belt upper cover.
14. Turn the crankshaft pulley, and align its groove with timing mark -T- of the timing belt cover.
15. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).
    
    
    

    

    Fig. Crankshaft pulley

16. Remove the crankshaft flange (A).
    
    
    

    

    Fig. Crankshaft flange

17. Remove the 5 bolts (B) and timing belt lower cover (A).
    
    
    

    

    Fig. Timing belt lower cover

To install:

1. Install timing belt lower cover and secure with the 5 bolts. Tighten and torque to 7 ft. lbs. (10 Nm).
2. Install crankshaft flange.
3. Install crankshaft pulley and secure with the crankshaft pulley bolt. Tighten and torque to 125-133 ft. lbs. (170-180 Nm).
4. Install the timing belt upper cover and secure with the 4 bolts. Tighten and torque to 7 ft. lbs. (10 Nm).
5. Install the water pump pulley and loosely secure with the 4 bolts.
6. Install the power steering, the air compressor and the alternator belts.
7. Tighten all 4 water pump pulley bolts to 7 ft. lbs. (10 Nm).
8. Install the stay plate and bolts. Tighten and torque to 55 ft. lbs. (69 Nm).
9. Install engine mounting brackets, secure with bolts and nuts. Tighten and torque to 80 ft. lbs. (94 Nm).
10. Lower the jack and remove from under the vehicle.
11. Install the RH side cover and secure with 2 bolts.
12. Install the RH front wheel.
13. Install the engine cover.

-------------------------------

TIMING,BELT, COVER,SPROCKETS:-----------

Removal & Installation

CAUTION

Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.

2.0L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Water pump pulley bolts

   Alternator bolt, loosen only

   Water pump pulley and drive belts

   Crankshaft pulley

   Timing belt cover(s)
   
   
3. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
4. Remove the timing belt tensioner and idler pulley.
5. Mark the timing belt with an arrow showing direction of rotation.
6. Remove the timing belt.







Fig. Proper alignment of the timing belt alignment marks for belt removal and installation-Hyundai 2.0L engines

To install:

1. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
2. Install the timing belt tensioner.
3. Install the idler pulley, if equipped. Tighten bolt to 32-41 ft. lbs. (43-55 Nm).
4. Position the timing belt over the camshaft sprocket, then over the crankshaft sprocket.
5. Tension the timing belt and tighten the tensioner pulley bolt to 32-41 ft. lbs. (43-55 Nm). When properly tensioned, the timing belt should deflect 0.16-0.24 in. (4-6mm) when a force of 5 lbs. (2.2kg) is placed on the longest span of the belt.
6. Turn the crankshaft sprocket one turn clockwise and realign the crankshaft sprocket timing mark.
7. Recheck the belt tension and adjust as necessary.
8. Install or connect the following:
   
   
   Timing belt cover(s)

   Crankshaft pulley

   A/C compressor belt

   Water pump pulley

   V belt

   Negative battery cable

   Engine with coolant
   
   

3.0L & 3.5L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Before servicing the vehicle, refer to the Precautions section.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Engine coolant

   Water pump pulley bolts

   Alternator bolt, loosen only

   Water pump pulley and drive belts

   Crankshaft pulley

   Timing belt cover(s)
   
   
4. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
5. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
6. Mark the timing belt with an arrow showing direction of rotation.
7. Remove the timing belt.
8. If defective, remove the timing belt tensioner.







Fig. Timing belt sprocket alignment mark positioning for belt removal and installation-3.0L and 3.5L engine

To install:

1. If necessary, install the timing belt tensioner.
2. Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine
3. Rotate the timing belt tensioner to the extreme counterclockwise position. Temporarily lock the tensioner in place.
4. Align the timing marks of the camshaft and crankshaft sprockets.
5. Install the timing belt on the crankshaft sprocket, then onto the rear camshaft sprocket.
6. Route the belt to the coolant pump pulley, the front camshaft sprocket and the timing belt tensioner.
7. Apply force counterclockwise to the rear camshaft sprocket with tension on the tight side of the belt and check that timing marks are aligned.
8. Loosen the tensioner bolt 1-2 turns and tighten the timing belt to a tension of 57-84 lbs. (260-380 N).
9. Turn the crankshaft two turns clockwise.
10. Readjust the sprocket timing marks and tighten the tensioner bolts.
11. Install the timing belt covers.
12. Install the crankshaft pulley and tighten to 108-116 ft. lbs. (150-160 Nm).
13. Install or connect the following:
    
    
    Timing belt cover(s)

    Crankshaft pulley

    A/C compressor belt

    Water pump pulley

    V belt

    Negative battery cable

    Engine with coolant