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

Crankshaft Damper (Balancer)

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the engine cover.
3. Remove the front right wheel and tire.
4. Remove the right side cover.
5. Remove the drive belt (A), the idler (B) and the tensioner (C).
   
   NOTE

   In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.
   
   
   
   
   

   

   Fig. Accessory belts location

6. Remove the timing belt upper cover (A).
   
   
   

   

   Fig. Timing belt upper cover location

Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover at the moment. No.1 cylinder piston at Top Dead Center (TDC).

Fig. Timing mark location

1. Sustain the engine oil pan with a jack.
   
   CAUTION

   Put a wooden or rubber block between the jack and the engine oil pan.
   
   
   
   
   

   

   Fig. Jack placement diagram

2. Remove the engine mounting bracket (A).
3. Remove the crankshaft damper pulley (A).
   
   
   

   

   Fig. Crankshaft damper pulley

4. Remove the crankshaft damper.

To install:

1. Install the crankshaft damper.
2. Install the crankshaft pulley. Torque mounting bolts to 133 ft. lbs. (180 Nm).
3. Replace the engine mounting bracket.
4. Lower the jack and remove from the vehicle.
5. Install the upper timing belt cover.
6. Making sure all timing and alignment marks match, install the drive belt, the idler and the tensioner.
7. Install the right side cover.
8. Install the right front tire and wheel.
9. Install the engine cover.

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

Cylinder Head

• REMOVAL & INSTALLATION

Removal & Installation

2.5L Engine

Fig. Cylinder head bolt loosening sequence-2.5L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Accessory drive belts

   Air intake assembly

   A/C compressor

   Alternator

   Power steering pump

   Front covers

   Timing belt

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Spark plug wires

   Distributor

   Fuel lines

   Intake manifold

   Exhaust manifolds

   Valve cover bolts

   Cylinder heads by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

1. Install or connect the following:
   
   
   New head gaskets

   Cylinder heads
   
   
2. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
3. For 2.5L engines, tighten the bolts in sequence as follows:
   1. Step 1: 18 ft. lbs. (25 Nm).
   2. Step 2: Plus 60-64 degree turn.
   3. Step 3: Plus 45-49 degree turn.

   
   
4. Install or connect the following:
   
   
   Valve covers

   Exhaust manifolds

   Intake manifold

   Fuel lines

   Distributor

   Spark plug wires

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Timing belt and front covers

   Power steering pump

   Alternator

   A/C compressor

   Air intake assembly

   Accessory drive belts

   Negative battery cable
   
   
5. Fill the cooling system.
6. Start the engine and check for leaks.

3.0L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Breather hose

   Air intake hose

   Vacuum hose

   Fuel hoses

   Intake manifold

   Spark plug wires

   Ignition coil

   Upper and lower timing belt covers

   Timing belt

   Camshaft sprockets

   Heat protector and exhaust manifold

   Water pump

   Rocker arm cover

   Camshafts

   Cylinder head and discard the gasket
   
   
5. Clean all mating surfaces of any residual gasket material.

To install:

Fig. Cylinder head torque sequence-3.0L XG300 Engine

1. Install or connect the following:
   
   
   New gasket with the identification mark facing the cylinder head

   Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)

   Camshafts

   Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)

   Water pump and torque the bolts to 16 ft. lbs. (22 Nm)

   Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)

   Camshaft sprockets

   Timing belt

   Upper and lower timing belt covers

   Ignition coil and spark plug wires

   Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)

   Fuel hoses

   Vacuum hose

   Air intake hose

   Breather hose

   Upper radiator hose

   Negative battery cable
   
   
2. Fill the cooling system to the proper level.
3. Start the vehicle, check for leaks and repair if necessary.

3.5L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Breather hose

   Air intake hose

   Vacuum hose

   Fuel hoses

   Intake manifold

   Spark plug wires

   Ignition coil

   Upper and lower timing belt covers

   Timing belt

   Camshaft sprockets

   Heat protector and exhaust manifold

   Water pump

   Rocker arm cover

   Camshafts
   
   
5. The cylinder head bolts should be loosened in sequence as shown.
6. Remove the cylinder head and discard the gasket.
7. Clean all mating surfaces of any residual gasket material. Cylinder head loosening sequence-3.5L engine

To install:

Fig. Cylinder head torque sequence-3.5L engine

1. Install or connect the following:
   
   
   New gasket with the identification mark facing the cylinder head

   Cylinder head and torque the bolts in sequence to 82 ft. lbs. (115 Nm)

   Camshafts

   Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)

   Water pump and torque the bolts to 16 ft. lbs. (22 Nm)

   Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)

   Camshaft sprockets

   Timing belt

   Upper and lower timing belt covers

   Ignition coil and spark plug wires

   Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)

   Fuel hoses

   Vacuum hose

   Air intake hose

   Breather hose

   Upper radiator hose

   Negative battery cable
   
   
2. Fill the cooling system to the proper level.
3. Start the vehicle, check for leaks and repair if necessary.

4-Cylinder Engines

Fig. Cylinder head bolt loosening sequence-1.5L, Elantra and Tiburon 2.0L engines

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Heater hose

   Air cleaner assembly

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Spark plug wires

   Distributor, if equipped

   Ignition coil

   Accessory drive belts

   Power steering pump and bracket

   Fuel lines

   Intake manifold

   Exhaust manifold

   Front cover

   Timing belt

   Valve cover bolts

   Cylinder head by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-1.5L, and Elantra and Tiburon 2.0L Engines

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

1. Install the cylinder head with a new gasket.
2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
3. For 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
   1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
   2. Step 2: Plus 60-65 degrees.
   3. Step 3: Plus 60-65 degrees.

   
   
4. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
5. For 2.4L engines, tighten the bolts in sequence as follows:
   1. Step 1: 14 ft. lbs. (20 Nm).
   2. Step 2: Plus 90 degrees.
   3. Step 3: Loosen all bolts in reverse of tightening order.
   4. Step 4: 14 ft. lbs. (20 Nm).
   5. Step 5: Plus 90 degrees.
   6. Step 6: Plus 90 degrees.

   
   
6. Install or connect the following:
   
   
   Valve cover

   Timing belt and front cover

   Exhaust manifold

   Intake manifold

   Fuel lines

   Power steering pump and bracket

   Accessory drive belts

   Ignition coil

   Distributor, if equipped

   Spark plug wires

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Air cleaner assembly

   Heater hose

   Upper radiator hose

   Negative battery cable
   
   
7. Fill the cooling system.
8. Start the engine and check for leaks.

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Heater hose

   Air cleaner assembly

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Spark plug wires

   Distributor, if equipped

   Ignition coil

   Accessory drive belts

   Power steering pump and bracket

   Fuel lines

   Intake manifold

   Exhaust manifold

   Front cover

   Timing belt

   Valve cover bolts

   Cylinder head by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

1. Install the cylinder head with a new gasket.
2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
3. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
4. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
   1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
   2. Step 2: Plus 60-65 degrees.
   3. Step 3: Plus 60-65 degrees.

   
   
5. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
6. For 2.4L engines, tighten the bolts in sequence as follows:
   1. Step 1: 14 ft. lbs. (20 Nm).
   2. Step 2: Plus 90 degrees.
   3. Step 3: Loosen all bolts in reverse of tightening order.
   4. Step 4: 14 ft. lbs. (20 Nm).
   5. Step 5: Plus 90 degrees.
   6. Step 6: Plus 90 degrees.

   
   
7. Install or connect the following:
   
   
   Valve cover

   Timing belt and front cover

   Exhaust manifold

   Intake manifold

   Fuel lines

   Power steering pump and bracket

   Accessory drive belts

   Ignition coil

   Distributor, if equipped

   Spark plug wires

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Air cleaner assembly

   Heater hose

   Upper radiator hose

   Negative battery cable
   
   
8. Fill the cooling system.
9. Start the engine and check for leaks.

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Heater hose

   Air cleaner assembly

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Spark plug wires

   Distributor, if equipped

   Ignition coil

   Accessory drive belts

   Power steering pump and bracket

   Fuel lines

   Intake manifold

   Exhaust manifold

   Front cover

   Timing belt

   Valve cover bolts

   Cylinder head by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

1. Install the cylinder head with a new gasket.
2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
3. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
4. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
   1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
   2. Step 2: Plus 60-65 degrees.
   3. Step 3: Plus 60-65 degrees.

   
   
5. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
6. For 2.4L engines, tighten the bolts in sequence as follows:
   1. Step 1: 14 ft. lbs. (20 Nm).
   2. Step 2: Plus 90 degrees.
   3. Step 3: Loosen all bolts in reverse of tightening order.
   4. Step 4: 14 ft. lbs. (20 Nm).
   5. Step 5: Plus 90 degrees.
   6. Step 6: Plus 90 degrees.

   
   
7. Install or connect the following:
   
   
   Valve cover

   Timing belt and front cover

   Exhaust manifold

   Intake manifold

   Fuel lines

   Power steering pump and bracket

   Accessory drive belts

   Ignition coil

   Distributor, if equipped

   Spark plug wires

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Air cleaner assembly

   Heater hose

   Upper radiator hose

   Negative battery cable
   
   
8. Fill the cooling system.
9. Start the engine and check for leaks.

V6 Engine
2.5L And 2.7L Engine

Fig. Cylinder head bolt loosening sequence-2.5L and 2.7L engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Accessory drive belts

   Air intake assembly

   A/C compressor

   Alternator

   Power steering pump

   Front covers

   Timing belt

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Spark plug wires

   Distributor

   Fuel lines

   Intake manifold

   Exhaust manifolds

   Valve cover bolts

   Cylinder heads by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

1. Install or connect the following:
   
   
   New head gaskets

   Cylinder heads
   
   
2. For 2.5L and 2.7L engines, tighten the bolts in sequence as follows:
   1. Step 1: 18 ft. lbs. (25 Nm).
   2. Step 2: Plus 60-64 degree turn.
   3. Step 3: Plus 45-49 degree turn.

   
   
3. Install or connect the following:
   
   
   Valve covers

   Exhaust manifolds

   Intake manifold

   Fuel lines

   Distributor

   Spark plug wires

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Timing belt and front covers

   Power steering pump

   Alternator

   A/C compressor

   Air intake assembly

   Accessory drive belts

   Negative battery cable
   
   
4. Fill the cooling system.
5. Start the engine and check for leaks.

2.5L Engine

Fig. Cylinder head bolt loosening sequence-2.5L engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Accessory drive belts

   Air intake assembly

   A/C compressor

   Alternator

   Power steering pump

   Front covers

   Timing belt

   Engine control wiring harness connectors

   Intake manifold vacuum lines

   Spark plug wires

   Distributor

   Fuel lines

   Intake manifold

   Exhaust manifolds

   Valve cover bolts

   Cylinder heads by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

1. Install or connect the following:
   
   
   New head gaskets

   Cylinder heads
   
   
2. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
3. For 2.5L engines, tighten the bolts in sequence as follows:
   1. Step 1: 18 ft. lbs. (25 Nm).
   2. Step 2: Plus 60-64 degree turn.
   3. Step 3: Plus 45-49 degree turn.

   
   
4. Install or connect the following:
   
   
   Valve covers

   Exhaust manifolds

   Intake manifold

   Fuel lines

   Distributor

   Spark plug wires

   Intake manifold vacuum lines

   Engine control wiring harness connectors

   Timing belt and front covers

   Power steering pump

   Alternator

   A/C compressor

   Air intake assembly

   Accessory drive belts

   Negative battery cable
   
   
5. Fill the cooling system.
6. Start the engine and check for leaks.

2.7L Engine

Fig. Cylinder head bolt loosening sequence- 2.7L engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Accessory drive belts

   Air intake assembly

   Radiator and heater hoses

   Engine control wiring harness connectors

   Fuel lines

   Brake booster vacuum hose

   Power steering pump

   Front covers

   Timing belt

   Intake manifold vacuum lines

   Ignition coil

   Intake manifold

   Exhaust manifolds

   Valve covers

   Camshafts

   Timing belt rear cover

   Cylinder heads by loosening the bolts in sequence

   Cylinder head and discard the gasket
   
   

To install:

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

1. Install or connect the following:
   
   
   New head gaskets

   Cylinder heads
   
   
2. Tighten the bolts in sequence as follows:
   1. Step 1: 18 ft. lbs. (25 Nm).
   2. Step 2: Plus 60-64 degree turn.
   3. Step 3: Plus 45-49 degree turn.

   
   
3. Install or connect the following:
   
   
   Timing belt rear cover. Tighten to 7-9 ft. lbs. (10-12 Nm).

   Camshafts

   Valve covers

   Timing belt

   Exhaust manifolds

   Power steering pump

   Intake manifold

   Brake booster vacuum hose

   Fuel lines

   Ignition coil

   Engine control wiring harness connectors

   Radiator and heater hoses

   Spark plug wires

   Air intake assembly

   Accessory drive belts

   Negative battery cable
   
   
4. Fill the cooling system.
5. Start the engine and check for leaks.

3.0L And 3.5L And 3.5L Engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Upper radiator hose

   Breather hose

   Air intake hose

   Vacuum hose

   Fuel hoses

   Intake manifold

   Spark plug wires

   Ignition coil

   Upper and lower timing belt covers

   Timing belt

   Camshaft sprockets

   Heat protector and exhaust manifold

   Water pump

   Rocker arm cover

   Camshafts

   Cylinder head and discard the gasket
   
   
5. Clean all mating surfaces of any residual gasket material.

To install:

Fig. Cylinder head torque sequence-3.0L and 3.5L engines

1. Install or connect the following:
   
   
   New gasket with the identification mark facing the cylinder head

   Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)

   Camshafts

   Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)

   Water pump and torque the bolts to 16 ft. lbs. (22 Nm)

   Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)

   Camshaft sprockets

   Timing belt

   Upper and lower timing belt covers

   Ignition coil and spark plug wires

   Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)

   Fuel hoses

   Vacuum hose

   Air intake hose

   Breather hose

   Upper radiator hose

   Negative battery cable
   
   
2. Fill the cooling system to the proper level.
3. Start the vehicle, check for leaks and repair if necessary.