Timing System - 2.4L - Except Hev: Removal & Installation Hyundai Sonata VI

Removal

Note. Mark all wiring and hoses to avoid mis-connection.

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1. Remove the engine cover.
2. Disconnect the battery negative terminal (A).
3. Remove the air duct (B).
4. Remove the air cleaner assembly. Disconnect the breather hose (A), the intensifier hose (B) and the brake booster vacuum hose (C). Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
5. Remove the RH front wheel.
6. Remove the under cover and RH side cover.
7. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No. 1 cylinder to the top dead center on compression stroke.
8. Disconnect the exhaust OCV (Oil control valve) connector (A).
9. Disconnect the ignition coil connectors (A) and the fuel pump connector (B), then remove the wiring protector (C).
10. Remove the ignition coils (A).
11. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
12. Disconnect PCSV (Purge control solenoid valve) connector (A) and loosen the vacuum & PCSV (Purge control solenoid valve) pipe assembly mounting bolts and nut.
13. Remove the high pressure pipe (A). (Refer to FUEL DELIVERY SYSTEM - 2.4L - EXCEPT HEV )
14. Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to FUEL DELIVERY SYSTEM - 2.4L - EXCEPT HEV )
15. Disconnect the PCV (Positive crankcase ventilation) hose (A).
16. Remove the front engine hanger (A).
17. Remove the cylinder head cover (A).
18. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
19. Remove the A/C compressor lower bolts (A).
20. Remove the A/C compressor bracket (A).
21. Drain the engine oil.
22. Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and 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 is result in damage of the SST. Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
23. Set the jack to the edge of ladder frame. NOTE: Put the wooden block between ladder frame and jack. CAUTION: Be careful not to damage the balance shaft & oil pump module.
24. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
25. Remove the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D). CAUTION: Tensioner pulley bolt is left-handed screw. NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. Install the SST (09231-3K000) 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 dust cover (A) on the bottom of the ladder frame and unfasten 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. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
26. Remove the drive belt tensioner (A).
27. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block. CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
28. Make sure that the key (A) of crankshaft is aligned with the mating surface of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
29. Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin (A) into the hole on the ratchet to hold the compressed piston. Remove the timing chain tensioner (B).
30. Remove the timing chain tensioner arm (A).
31. Remove the timing chain (A).
32. Remove the timing chain guide (A).
33. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
34. Remove the balance shaft chain. (Refer to LUBRICATION SYSTEM )

Note. Mark all wiring and hoses to avoid mis-connection.

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1. Remove the engine cover.
2. Disconnect the battery negative terminal (A).
3. Remove the air duct (B).
4. Remove the air cleaner assembly. Disconnect the breather hose (A), the intensifier hose (B) and the brake booster vacuum hose (C). Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
5. Remove the RH front wheel.
6. Remove the under cover and RH side cover.
7. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No. 1 cylinder to the top dead center on compression stroke.
8. Disconnect the exhaust OCV (Oil control valve) connector (A).
9. Disconnect the ignition coil connectors (A) and the fuel pump connector (B), then remove the wiring protector (C).
10. Remove the ignition coils (A).
11. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
12. Disconnect PCSV (Purge control solenoid valve) connector (A) and loosen the vacuum & PCSV (Purge control solenoid valve) pipe assembly mounting bolts and nut.
13. Remove the high pressure pipe (A). (Refer to FUEL DELIVERY SYSTEM - 2.4L - EXCEPT HEV )
14. Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to FUEL DELIVERY SYSTEM - 2.4L - EXCEPT HEV )
15. Disconnect the PCV (Positive crankcase ventilation) hose (A).
16. Remove the front engine hanger (A).
17. Remove the cylinder head cover (A).
18. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
19. Remove the A/C compressor lower bolts (A).
20. Remove the A/C compressor bracket (A).
21. Drain the engine oil.
22. Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and 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 is result in damage of the SST. Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
23. Set the jack to the edge of ladder frame. NOTE: Put the wooden block between ladder frame and jack. CAUTION: Be careful not to damage the balance shaft & oil pump module.
24. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
25. Remove the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D). CAUTION: Tensioner pulley bolt is left-handed screw. NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley. Install the SST (09231-3K000) 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 dust cover (A) on the bottom of the ladder frame and unfasten 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. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
26. Remove the drive belt tensioner (A).
27. Remove the engine support bracket (A).
28. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block. CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
29. Make sure that the key (A) of crankshaft is aligned with the mating surface of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
30. Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin (A) into the hole on the ratchet to hold the compressed piston. Remove the timing chain tensioner (B).
31. Remove the timing chain tensioner arm (A).
32. Remove the timing chain (A).
33. Remove the timing chain guide (A).
34. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
35. Remove the balance shaft chain. (Refer to LUBRICATION SYSTEM )