Timing System - g3.5 DOHC Hyundai Santa Fe II рестайлинг

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Removal

Note. Mark all wiring and hoses to avoid misconnection.

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1. Disconnect the battery negative terminal.
2. Remove the engine cover (A).
3. Remove the air duct (B).
4. Remove the air cleaner assembly. Disconnect the breather hose (A) and the BARO sensor connector (B). Disconnect the air intake hose and then remove the air cleaner assembly (C). Tightening torque Hose clamp bolt: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft) Air cleaner assembly bolts: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
5. Remove the under cover.
6. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.
7. Remove the radiator upper hose (A) and lower hose (B).
8. Disconnect the wiring connectors, harness clamps and hoses from the engine. RH front, rear oxygen sensor connector (A). VIS connector (B). RH exhaust camshaft OCV connector (C). RH ignition coil connector (D). RH injector connector (E). VCM connector (F). Power steering switch connector (G). LH exhaust camshaft OCV connector (A). LH/RH intake camshaft OCV connector (B). Oil pressure switch connector (C). Knock sensor connector (D). VPS connector (E). Condenser connectors (F). Ground (G). Disconnect LH front oxygen sensor connector (A). Disconnect alternator connector (A). LH ignition coil connectors (A). LH injector connectors (B). VIS connector (C). LH intake CMPS connector (D). MAP sensor connector (A). PCSV connector (B). RH intake CMPS connector (A). Knock sensor connector (B). OTS connector (C). ETC connector (D). RH exhaust CMPS connector (E). WTS & gauge unit connector (A). LH exhaust CMPS connector (A). LH rear oxygen sensor connector (B). CKPS connector (C).
9. Disconnect the PCSV hose (A), fuel hose (B).
10. Drain the engine oil.
11. Remove the lower oil pan (A). Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan. Cut off applied sealer and remove the lower oil pan. NOTE: Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow. After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame. Do not turn over the SST abruptly without tapping. It be result in damage of the SST. Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
12. Install the jack to the edge of ladder frame (A) to support the engine. NOTE: Insert the rubber block between jack and ladder frame.
13. Disconnect the ground cable, and then remove the engine mounting bracket (A). Tightening torque: Bolts (B) & Nut (C): 63.8 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft) Nut (D): 78.5 ~ 107.9 N.m (8.0 ~ 11.0 kgf.m, 57.9 ~ 79.6 lb-ft)
14. Remove the surge tank (A). (Refer to «INTAKE AND EXHAUST SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/exhaust/#intake-and-exhaust-system-g35-dohc).) NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
15. Disconnect the RH ignition coil connectors (A) and the RH injector connectors (B).
16. Remove the LH/RH ignition coils (A).
17. Remove the exhaust OCV cap (A), and then remove the LH, RH cylinder head covers.
18. Remove the drive belt (A).
19. Lift up the engine assembly by using the jack.
20. Remove the power steering pump (A). (Refer to «HYDRAULIC POWER STEERING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/manual-power-steering/#hydraulic-power-steering-system).)
21. Remove the air conditioner compressor (A). (Refer to «AIR CONDITIONING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/automatic-hvac-system/#air-conditioning-system).)
22. Remove the alternator (A).
23. Remove the drive belt idler (A).
24. Remove the drive belt auto tensioner (A).
25. Remove the water pump pulley (A).
26. Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft clockwise one revolution (360°). NOTE: Do not rotate engine counterclockwise.
27. Remove the crankshaft pulley (A). NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. * Install the SST (09231-2B100) to hold the ring gear after removing the starter. * Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. Remove the front muffler. (Refer to Intake And Exhaust system) Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B). (Scheme 252): Identifying the dust cover (A) on the bottom of the upper oil pan and the two transaxle mounting bolts (B). Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. Fasten the two transaxle mounting bolts in the original mounted holes. (Scheme 253): Identifying SST (09231-3D100) Ring Gear Holder Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely. (Scheme 254): Installed Position Of SST (09231-3D100) Ring Gear Holder
28. Remove the water pump (A) and gasket (B).
29. Remove the timing chain cover (A). CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. NOTE: Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
30. Remove the oil pump chain cover (A).
31. Remove the oil pump chain tensioner assembly (A).
32. Remove the oil pump chain guide (A).
33. Install a set pin after compressing the RH timing chain tensioner.
34. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
35. Remove the RH timing chain guide (A) and RH timing chain (B).
36. Remove the oil pump chain sprocket (A) and oil pump chain (B).
37. Remove the crankshaft sprocket (A) (O/P & RH camshaft drive).
38. Install a set pin after compressing the LH timing chain tensioner.
39. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
40. Remove the LH timing chain guide (A) and LH timing chain (B).
41. Remove the crankshaft sprocket (A). (LH camshaft drive).
42. Remove the tensioner adapter assembly (A).

Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm

1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

Drive belt, Idler, Belt tensioner pulley

1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
2. Check the belt tensioner for excessive dust, crack, and damage. Replace if necessary.
3. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.
4. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.

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1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
2. Install the tensioner adapter assembly (A).
3. Install the crankshaft sprocket (A). (LH camshaft drive).
4. Install the LH timing chain guide (A) and LH timing chain (B). Tightening torque: 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft) NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket --> Timing chain guide --> Exhaust camshaft sprocket --> Intake camshaft sprocket. The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
5. Install the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B). Tightening torque 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
6. Install the crankshaft sprocket (A) (O/P & RH camshaft drive).
7. Install the oil pump chain sprocket (A) and oil pump chain (B). Tightening torque: 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
8. Install the RH timing chain guide (A) and RH timing chain (B). Tightening torque: A: 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft) NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure. Crankshaft sprocket -->Timing chain guide --> Intake camshaft sprocket --> Exhaust camshaft sprocket. The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
9. Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B). Tightening torque 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
10. Install the oil pump chain guide (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
11. Install the oil pump chain tensioner assembly (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
12. Pull out the pins of hydraulic tensioner (LH & RH).
13. Install the oil pump chain cover (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
14. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark. NOTE: Always turn the crankshaft clockwise. Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.
15. Install the timing chain cover. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc. Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied. Bead width: 2.5mm (0.1in.) After applying liquid sealant TB1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity. NOTE: Fill the T-joint area (6EA *) with sealant. Apply sealant all around the dowel pin hole (2EA). Install the new gasket (A) to the timing chain cover. NOTE: During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts. 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 to be in exact position. Tightening torque B (17):18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft) C (4):9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) D (2):58.8 ~ 68.8N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft) F (2):24.5 ~ 26.5N.m (2.5 ~ 2.7kgf.m, 18.1 ~ 19.5lb-ft) G (4):21.6 ~ 23.5N.m (2.2 ~ 2.4kgf.m, 15.9 ~ 17.4lb-ft) H (1):9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) I (1):9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) J (1):9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) K (4):9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) L (1):21.6 ~ 26.5N.m (2.2 ~ 2.7kgf.m, 15.9 ~ 19.5lb-ft) - New bolt The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
16. Using SST (09231-3C100), install timing chain cover oil seal.
17. Install the lower oil pan (A). Using a gasket scraper, remove all the old packing material from the gasket surfaces. Before assembling the oil pan, the liquid sealant TB 1217H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5mm (0.1in.) CAUTION: Clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant. When applying sealant gasket, sealant must not be protruded into the inside of oil pan. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. Install the oil pan (A). Uniformly tighten the bolts in several passes. Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
18. Install the crankshaft pulley (A). Tightening torque: 284.4 ~304.0N.m (29.0~31.0kgf.m, 209.8~224.2lb-ft) NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. * Install the SST (09231-2B100) to hold the ring gear after removing the starter. * Remove the SST (09231-3D100) to hold the ring gear. Install the front muffler. (Refer to Intake And Exhaust system) Install the dust cover (A) on the bottom of the upper oil pan and fasten the two transaxle mounting bolts (B). see scheme 86: Identifying the dust cover (A) on the bottom of the upper oil pan and the two transaxle mounting bolts (B). Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. Fasten the two transaxle mounting bolts in the original mounted holes. see scheme 87: Identifying SST (09231-3D100) Ring Gear Holder Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely. see scheme 88: Identifying SST (09231-3D100) Ring Gear Holder
19. Install the water pump pulley (A). Tightening torque: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
20. Install the drive belt auto tensioner (A). Tightening torque Bolt (B):81.4 ~ 85.3N.m (8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft) Bolt (C):17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)
21. Install the alternator (A). (Refer to «ALTERNATOR»(/hyundai/santa-fe/ii-2010-2012/remont/charging-system/#charging-system-g35-dohc).) Tightening torque: 26.5 ~ 33.3N.m (2.7 ~ 3.4kgf.m, 19.5 ~ 24.6lb-ft)
22. Install the air conditioner compressor (A). (Refer to «AIR CONDITIONING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/automatic-hvac-system/#air-conditioning-system).)
23. Install the power steering pump (A). (Refer to «HYDRAULIC POWER STEERING SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/manual-power-steering/#hydraulic-power-steering-system).)
24. Install the drive belt (A).
25. Install the LH/RH cylinder head cover (A). CAUTION: Install the cylinder head cover under the exhaust OCV cap is removed. To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover. After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width: 2.5mm (0.1in.) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled. Install the cylinder head cover bolts as following method. Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) CAUTION: Do not reuse cylinder head cover gasket. Install the exhaust OCV cap (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
26. Install the surge tank. (Refer to «INTAKE AND EXHAUST SYSTEM»(/hyundai/santa-fe/ii-2010-2012/remont/exhaust/#intake-and-exhaust-system-g35-dohc).)
27. Install the other parts with reverse order of removal. NOTE: Refill engine oil. Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion. 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 lines. Refill radiator and reservoir tank with engine coolant. Bleed air from the cooling system. Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.) Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put radiator cap on tightly, then run the engine again and check for leaks.

See also:
• INTAKE AND EXHAUST SYSTEM
• HYDRAULIC POWER STEERING SYSTEM
• AIR CONDITIONING SYSTEM
• ALTERNATOR