Engine Mechanical System

Specifications
Description Specifications Limit
General
Type V-type, DOHC
Number of cylinders 6
Bore 92mm(3.6220in.)
Stroke 83.8mm(3.2992in.)
Total displacement 3,342cc(203.94cu.in.)
Compression ratio 11.5 : 1
Firing order 1-2-3-4-5-6
Valve timing
Opens(ATDC) 10°
Intake
Closes(ABDC) 70°
Opens(BBDC) 52°
Exhaust
Closes(ATDC) 0°
Cylinder head
Less than 0.05mm (0.0019in.)
Flatness of gasket surface
[Less than 0.02mm (0.0008in.) / 150x150]
Less than 0.1mm(0.0039in.)
Intake
Flatness of manifold [Less than 0.03mm(0.001in.) / 110x110]
mounting Less than 0.1mm(0.0039in.)
Exhaust
[Less than 0.03mm(0.001in.) / 110x110]
Camshaft
LH Intake 46.6mm (1.835in.)

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Camshaft Exhaust 45.8mm (1.8031in.)
Cam height
RH Intake 46.6mm (1.835in.)

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Camshaft Exhaust 45.8mm (1.8031in.)

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No.1: 27.964 ~ 27.978mm (1.1009 ~ 1.1015in.)
Intake

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Journal outer LH, RH No.2,3,4: 23.954 ~ 23.970mm(0.9430 ~ 0.9437in.)
diameter camshaft No.1: 27.964 ~ 27.978mm(1.1009 ~ 1.1015in.)
Exhaust

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No.2,3,4: 23.954 ~ 23.970mm(0.9430 ~ 0.9437in.)

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No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.)
Intake
Bearing oil LH, RH No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
clearance camshaft No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.)
Exhaust
No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
End play 0.02 ~ 0.18mm (0.0008 ~ 0.0071in.)
Valve
Intake 105.27mm(4.1445in.)
Valve length
Exhaust 105.50mm (4.1535in.)
Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Stem outer diameter
Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)
Face angle 45.25° ~ 45.75°
Thickness of Intake 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.)
valvehead(margin) Exhaust 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.)
Valve stem to valve Intake 0.020 ~ 0.047mm (0.00078 ~ 0.00185in.) 0.07mm (0.00275in.)
guide clearance Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.) 0.09mm (0.00354in.)
Valve guide
Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Inner diameter
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Intake 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Length
Exhaust 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Valve seat
Width of seat Intake 1.15 ~ 1.45mm(0.05118 ~ 0.05709in.)
contact Exhaust 1.35 ~ 1.65mm(0.05315 ~ 0.06496in.)
Intake 44.75° ~ 45.20°
Seat angle
Exhaust 44.75° ~ 45.20°
Valve spring
Free length 45.5mm (1.7913in.)
 19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.)
Load
42.3±1.3kg/23.8mm (93.3±2.9 lb/0.9370in.)
Out of squareness Less than 1.5°
MLA
Intake 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
MLA outer diameter
Exhaust 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
Cylinder head tappet Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)
bore inner diameter Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)
MLA to tappet bore Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm (0.0027in.)
clearance Exhaust 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm (0.0027in.)
Valve clearance (At 20°C [68°F])
0.10 ~ 0.30mm
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
(0.0039 ~ 0.0118in.)
0.20 ~ 0.40mm
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
(0.0078 ~ 0.0157in.)
Cylinder block
Cylinder bore 92.00 ~ 92.03mm (3.6220 ~ 3.6232in.)
Less than 0.05mm (0.0019in.)
Flatness of gasket surface
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
Piston outer diameter 91.96 ~ 91.99mm(3.6204 ~ 3.6216in.)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
No. 1 ring groove 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.)
Ring groove width No. 2 ring groove 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.)
Oil ring groove 2.01 ~ 2.025mm (0.0791 ~ 0.0797in.)
Piston ring
No. 1 ring 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) 0.1mm (0.004in.)

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Side clearance No. 2 ring 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) 0.1mm (0.004in.)

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Oil ring 0.02 ~ 0.06mm (0.0008 ~ 0.0024in.) 0.2mm (0.008in.)
No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) 0.6mm (0.0236in.)

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End gap No. 2 ring 0.37 ~ 0.52mm (0.0145 ~ 0.0204in.) 0.7mm (0.0275in.)

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Oil ring 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.) 0.8mm (0.0315in.)

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Piston pin
Piston pin outer diameter 21.097 ~ 22.000mm (0.8305 ~ 0.8661in.)

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Piston pin hole inner diameter 22.004 ~ 22.010mm (0.8662 ~ 0.8665in.)
Piston pin hole clearance 0.004 ~ 0.013mm (0.00015 ~ 0.00051in.)
Connecting rod small end inner diameter 22.005 ~ 22.016mm (0.8663 ~ 0.8667in.)
Connecting rod small end hole clearance 0.005 ~ 0.019mm (0.00019 ~ 0.00074in.)
Connecting rod
Connecting rod big end inner diameter 58.000 ~ 58.018mm(2.2834 ~2.2842in.)
Connecting rod bearing oil clearance 0.044 ~ 0.062mm (0.0017 ~ 0.0024in.)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)
Crankshaft
Main journal outer diameter 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Pin journal outer diameter 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)
Main bearing oil clearance 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.)
End play 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)
Oil pump
Regulating pressure 5.0 ~ 5.5bar
Engine oil
Total 6.5L (6.87 US qt, 5.72lmp qt, 1.72 US.gal) Total Engine oil
Oil quantity Oil pan 6.0L (6.34 US qt, 5.28lmp qt, 1.58 US.gal)
Drain and refill 5.7L (6.02 US qt, 5.01lmp qt, 1.50 US.gal) Including oil filter
Oil grade If not available, refer to
the recommended ACEA,
Recommendation 5W-30 / A5 API or ILSAC
classification and SAE
viscosity number.
Satisfy the requirement of
Classification ACEA A3, A5 or above the ACEA, API or ILSAC
classification.
 SAE viscosity grade Recommended SAE viscosity number Refer to the "Lubrication
System".
130kPa(1.32kgf/cm², 18.77psi) Oil temperature (oil pan):
Oil pressure (at 1000rpm) 110±2°C (230±35.6°F)
[at 1000rpm,110°C(230°F)]
Cooling system
Cooling method Forced circulation with water pump
Coolant quantity 8.4L(8.87US qt, 7.38lmp qt, 2.21US.gal)
Type Wax pellet type
Opening temperature 88±2°C (109.4±3.6°F)
Thermostat
Fully opened temperature 100°C (212°F)
Full lift 10mm (0.3937in.) MIN
93.16 ~ 122.58kpa
Main valve opening pressure
(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)
Radiator cap
0 ~ 6.86 kpa
Vacuum valve opening pressure
(0 ~ 0.07kg/cm², 0 ~ 0.99psi)

Sealant
Description Specifications
Cylinder head and cylinder block between gap
Timing chain cover
Cylinder head cover
TB 1217H
Cylinder head
(Hyundai Gray RTV)
Oil seal case
Lower oil pan
Upper oil pan

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Tightening Torques

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Item Quantity Nm kgf.m lb-ft

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Engine Mounting

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Engine mounting bracket to body fixing bolt 4 58.8 ~ 73.5 6.0 ~ 7.5 43.3 ~ 54.2
Engine mounting support bracket to engine

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1 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
mounting insulator fixing nut

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Engine mounting support bracket to engine
2 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
support bracket fixing bolt
Engine mounting support bracket to engine
1 78.5 ~ 98.1 8.0 ~ 10.0 57.9 ~ 72.3
support bracket fixing nut
Roll rod bracket to sub frame fixing bolt 2 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0
Roll rod insulator to roll rod mounting support
1 107.9 ~ 127.5 11.0 ~ 13.0 79.6 ~ 94.0
bracket fixing nut
Timing system
Drive belt idler bolt 1 53.9 ~ 57.9 5.5 ~ 5.9 39.8 ~ 42.7
Drive belt auto tensioner bolt(M12) 1 81.4 ~ 85.3 8.3 ~ 8.7 60.0 ~ 62.9
Drive belt auto tensioner bolt(M8) 1 17.7 ~ 21.6 1.8 ~ 2.2 13.0 ~ 15.9
Crankshaft pulley bolt 1 284.4 ~ 304.0 29.0 ~ 31.0 209.8 ~ 224.2
Timing chain cover bolt A 17 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9
Timing chain cover bolt B 2 24.5 ~ 26.5 2.5 ~ 2.7 18.1 ~ 19.5
Timing chain cover bolt C 1 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6
Timing chain cover bolt D 1 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6
Timing chain cover bolt E 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Timing chain auto tensioner arm bolt 2 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9
Timing chain guide bolt 4 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Timing chain cam to cam guide bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Cylinder head
Ignition coil bolt (LH/RH) 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Spark plug (LH/RH) 6 14.7 ~ 24.5 1.5 ~ 2.5 10.8 ~ 18.1
Cylinder head cover bolt (LH/RH) 38 [3.9~5.9] + [9.8~11.8] [0.4~0.6] + [1.0~1.2] [2.9~4.3] + [7.2~8.7]
CVVT bolt (LH/RH) 4 64.7 ~ 76.5 6.6 ~ 7.8 47.7 ~ 56.4
Camshaft bearing cap bolt (LH/RH) 32 [5.9] + [9.8~11.8] [0.6] + [1.0~1.2] [4.3] + [7.2~8.7]
[37.3~41.2] + [118~122°] + [3.8~4.2] + [118~122°] + [27.5~30.4] + [118~122°] +
Cylinder head bolt (LH/RH) 16
[88~92°] [88~92°] [88~92°]
Cylinder head bolt (RH rear) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Engine hanger bolt (Front) 1 44.1 ~ 53.6 4.5 ~ 5.5 32.5 ~ 39.8
Engine hanger bolt (Rear) 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Exhaust OCV(oil control valve) bolt (LH/RH) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Intake OCV(oil control valve) bolt (LH/RH) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Fuel pump bracket bolt 4 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Cylinder block
Connecting rod bolt 12 [27.5~31.3] + [68~72°] [2.8~3.2] + [68~72°] [20.2~23.1] + [68~72°]
Main bearing cap inner bolt(M11) 8 [49.0] + [90°] [5.0] + [90°] [36.2] + [90°]
Main bearing cap outer bolt(M8) 8 [19.6] + [120°] [2.0] + [120°] [14.5] + [120°]
Main bearing cap side bolt(M8) 8 29.4 ~ 31.4 3.0 ~ 3.2 21.7 ~ 23.1
Oil drain cover bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil jet bolt 3 27.5 ~ 31.3 2.8 ~ 3.2 20.2 ~ 23.1
Rear oil seal case bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Baffle plate bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Knock sensor bolt (LH/RH) 2 15.7 ~ 23.5 1.6 ~ 2.4 11.6 ~ 17.4
Drive plate bolt 8 71.54 ~ 75.46 7.3 ~ 7.7 52.80 ~ 55.69
Upper oil pan bolt 18 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Lubrication system
Oil drain bolt 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5
Oil pump bolt 3 20.6 ~ 22.6 2.1 ~ 2.3 15.2 ~ 16.6
Oil filter body bolt 4 19.6 ~ 21.6 2.0 ~ 2.2 14.5 ~ 15.9
Oil filter cap 1 34.3 3.5 25.3
Oil level gauge & water inlet pipe bolt 1 18.6 ~ 22.6 1.9 ~ 2.3 13.7 ~ 16.6

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Lower oil pan bolt 13 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

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Oil pump chain cover bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump chain tensioner bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

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Oil pump chain sprocket bolt 1 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9

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Cooling system
Water pump bolt A 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

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Water pump bolt B 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

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Water pump bolt C 1 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5
Water pump bolt D 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt E 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt F 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Water pump bolt G 4 21.6 ~ 23.5 2.2 ~ 2.4 15.9 ~ 17.4
Water pump pulley bolt 4 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Water temp. control nut 4 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Water temp. control bolt 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Water center pipe bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Intake and exhaust system
Intake air hose clamp bolt 1 2.9 ~ 4.9 0.3 ~ 0.5 2.2 ~ 3.6
Air cleaner assembly bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Intake manifold bolt 8 [3.9~5.9] + [26.5~31.4] [0.4~0.6] + [2.7~3.2] [2.9~4.3] + [19.5~23.1]
Surge tank bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Surge tank grommet bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Surge tank nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Surge tank stay bolt 2 27.5 ~ 31.3 2.8 ~ 3.2 20.2 ~ 23.1
Exhaust manifold nut (LH/RH) 16 49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8
Heat protector bolt (LH/RH) 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Exhaust manifold stay bolt (LH/RH) 4 24.5 ~ 35.3 2.5 ~ 3.6 18.1 ~ 26.0
Muffler nut 16 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Engine Mechanical System

Compression Pressure Inspection

 If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up engine until the normal operating temperature(80~95°C(176-203°F)).

2. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
3. Remove the ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
4. Remove the spark plugs.
(Refer to Engine Electrical System - "Spark Plug")
5. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Fully open the throttle.
(3) Crank the engine over 7 times to measure compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.

(4) Repeat step 1) though 3) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure :
1,029kPa (10.5kgf/cm², 149psi) (250~400 rpm)
Minimum pressure :

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882kPa (9.0kgf/cm², 128psi)

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Difference between each cylinder :
98kPa (1.0kg/cm², 14psi) or less

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(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole

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and repeat step 1) through 3) for cylinders with low compression.
a. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.

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b. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.

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6. Reinstall the spark plugs.
7. Install the ignition coils and ignition connectors.
8. Install the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")

Valve Clearance Inspection And Adjustment

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C(68°F)) and cylinder head is installed
on the cylinder block.

1. Remove the cylinder head cover.

(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
2. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.
 (2) Check that the mark 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°).

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Do not rotate engine counterclockwise.

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3. Inspect the valve clearance.

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(1) With No.1 cylinder at TDC inspect clearances only on the valves shown in diagram below.

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Measurement method.
a. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
b. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement
adjusting tappet.
Valve clearance
Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.)

(2) Turn the crankshaft pulley clockwise one revolution (360°) and align the groove with timing mark "T" of the lower timing chain cover.
(3) With No.4 cylinder at TDC inspect clearances only the valves shown in diagram below. (Refer to procedure step 1.)
4. Adjust the intake and exhaust valve clearance.
(1) Set the No.1 cylinder to the TDC/compression.
(2) Remove the timing chain.

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.

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(3) Remove the fuel pump bracket (A).

(4) Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).

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(5) Remove the LH/RH camshaft assembly (A).

(6) Remove the tappets.
(7) Measure the thickness of the removed tappet using a micrometer.

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(8) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T :Thickness of removed tappet
A :Measured valve clearance
N :Thickness of new tappet
Intake :N = T + [A - 0.20mm(0.0079in.)]
Exhaust :N = T + [A - 0.30mm (0.0118in.)]

(9) Select a new tappet with a thickness as close as possible to the calculated value.

Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.)

(10) Place a new tappet on the cylinder head.

Apply engine oil at the selected tappet on the side and top surface.

(11) Install the intake and exhaust camshaft.

(12) Install the bearing caps.
(Refer to Cylinder Head Assembly - "Camshaft")
(13) Install the timing chain.
(Refer to Timing System - "Timing Chain")
(14)
 Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing
marks.

(15) Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C [68°F])
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

Engine Mechanical System

Troubleshooting
Symptom Suspect area Remedy
Engine misfire with abnormal internal lower Worn crankshaft bearings. Replace the crankshaft and bearings as
engine noises. Loose or damaged engine drive plate. required.
Repair or replace the drive plate as required.

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Worn piston rings. Inspect the cylinder for a loss of compression.
(Oil consumption may or may not cause the Repair or replace as required.

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engine to misfire.)
Worn crankshaft thrust bearings Replace the crankshaft and bearings as

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required.

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Engine misfire with abnormal valve train noise. Stuck valves. Repair or replace as required.
(Carbon buildup on the valve stem)

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Excessive worn or mis-aligned timing chain. Replace the timing chain and sprocket as

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required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with coolant consumption. • Faulty cylinder head gasket and/or cranking • Inspect the cylinder head and engine block
or other damage to the cylinder head and for damage to the coolant passages and/or
engine block cooling system a faulty head gasket.
• Coolant consumption may or may not • Repair or replace as required.
cause the engine to overheat.
Engine misfire with excessive oil consumption. Worn valves, guides and/or valve stem oil Repair or replace as required.
seals.
Worn piston rings. • Inspect the cylinder for a loss of
(Oil consumption may or may not cause the compression.
engine to misfire) • Repair or replace as required.
Engine noise on start-up, but only lasting a few Incorrect oil viscosity. • Drain the oil.
seconds. • Install the correct viscosity oil.

Minor engine clatter sound immediately

upon cold start for very brief period may be
normal.

Upper engine noise,regardless of engine Low oil pressure. Repair or replace as required.
speed. Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as
required.
Worn camshaft lobes. • Inspect the camshaft lobes.
•
 Replace the timing camshaft and valve
lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides, then
repair as required.
Stuck valves. Carbon on the valve stem or Inspect the valves and valve guides, then
valve seat may cause the valve to stay open. repair as required.
Worn drive belt, idler, tensioner and bearing. Replace as required.
Lower engine noise,regardless of engine Low oil pressure. Repair as required.
speed. Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the oil pump • Inspect the oil pan.
screen. • Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged or restricted. • Inspect the oil pump screen.
• Repair or replace as required.
Excessive piston-to-cylinder bore clearance. • Inspect the piston, piston pin and cylinder
bore.
• Repair as required.
Excessive piston pin-to-piston clearance. • Inspect the piston, piston pin and the
connecting rod.
• Repair or replace as required.
Excessive connecting rod bearing clearance Inspect the following components and repair
as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft pin journals.
Excessive crankshaft bearing clearance. Inspect the following components, and repair
as required.
• The crankshaft bearings.
• The crankshaft main journals.

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• The cylinder block.

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Incorrect piston, piston pin and connecting rod • Verify the piston pins and connecting rods
installation are installed correctly.

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• Repair as required.

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Engine noise under load. Low oil pressure Repair or replace as required.
Excessive connecting rod bearing clearance . Inspect the following components and repair

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as required :
• The connecting rod bearings.

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• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components, and repair
as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Engine will not crank-crankshaft will not rotate. Hydraulically locked cylinder. 1) Remove spark plugs and check for fluid.
• Coolant/antifreeze in cylinder. 2) Inspect for broken head gasket.
• Oil in cylinder. 3) Inspect for cracked engine block or cylinder
• Fuel in cylinder. head.
4) Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain and/or 1) Inspect timing chain and gears.
timing chain gears. 2) Repair as required.
Material in cylinder. 1) Inspect cylinder for damaged components
• Broken valve and/or foreign materials.
• Piston material 2) Repair or replace as required.
• Foreign material
Seized crankshaft or connecting rod bearings. 1) Inspect crankshaft and connecting rod
bearing.
2) Repair as required.
Bent or broken connecting rod. 1) Inspect connecting rods.
2) Repair as required.
Broken crankshaft. 1) Inspect crankshaft.
2) Repair as required.

Engine Mechanical System

 Special Service Tools
Tool (Number and name) Illustration Use
Crankshaft front oil seal installer Installation of the front oil seal
(09231-3C100)

Ring gear stopper Removal and installation of crankshaft pulley bolt

(09231-2B100)

Ring gear stopper Removal and installation of crankshaft pulley bolt.

(09231-3D100)

Torque angle adapter Installation of bolts & nuts needing an angular method
(09221-4A000)

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Valve stem seal remover Removal of the valve stem seal

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(09222-29000)

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Valve stem seal installer Installation of the valve stem seal
(09222-3C100)

Valve spring compressor & holder Removal and installation of the intake or exhaust valves
(09222-3K000) A : 09222-3K000
(09222-3K100) B : 09222-3K100 (holder)

Crankshaft rear oil seal installer Installation of the crankshaft rear oil seal
(09231-3C200) A : 09231-3C200
(09231-H1100) B : 09231-H1100

Oil pan remover Removal of oil pan

(09215-3C000)
 Engine Mechanical System

Components Location

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1. Engine cover

Engine Mechanical System

Removal and Installation

1. Remove the engine cover (A).
 • Lift up the lower end of engine cover, then left and right alternately.
• When installing, confirm that the mounting rubber insulators has been installed.

2. Installation is reverse order of removal

Engine Mechanical System

Components

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1. Engine room front under cover
2. Engine room RH Under cover
3. Engine room LH Under cover

Engine Mechanical System

Removal and Installation

1. Remove the engine room under cover (A) and (B).
Tightening torque:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

• When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting
bracket assembly.

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2. Installation is reverse order of removal

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Engine Mechanical System

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Components

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1. Transaxle mounting bracket 4. Engine mounting bracket

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2. Roll road bracket 5. Engine mounting support bracket

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3. Sub frame

Engine Mechanical System

Removal and Installation

[Engine mounting support bracket]
1. Install the jack to the edge of upper oil pan (A) to support the engine.

Insert the rubber block between jack and upper oil pan.

2. Disconnect the ground cable (A), and then remove the engine mounting support bracket (B).
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
3. Install in the reverse order of removal.

[Engine mounting bracket]

1. Remove the reservoir tank.
(Refer to Cooling System - "Reservoir Tank")
2. Remove the engine mounting support bracket (A).
Tightening torque:
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

3. Remove the engine mounting bracket (B).

Tightening torque:
58.8 ~ 73.5N.m (6.0 ~ 7.5kgf.m, 43.3 ~ 54.2lb-ft)

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4. Install in the reverse order of removal.

[Roll rod bracket]

1. Remove the engine room under cover.
2. Remove the roll rod bracket (A).
Tightening torque
Bolt (B):
107.9 ~ 127.5N.m (11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)
Bolts (C):
49.0 ~ 63.7N.m ( 5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

Do not reuse : Bolt (B) (Loctited)

3. Install in the reverse order of removal.

Engine Mechanical System

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

1. Release the residual pressure in fuel line.

(Refer to Fuel System - "Fuel Delivery System")
2. Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
3. Remove the engine cover.
4. Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
5. Remove the engine room under cover.
6. Drain the engine coolant.
(Refer to Cooling System - "Coolant")
7. Remove the radiator upper hose and lower hose.
(Refer to Cooling System - "Radiator Hose")

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8. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
9. Disconnect the (+) cable (A) from the junction box.

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10. Remove the ECM.

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(1) Disconnect the Engine contol module(ECM) connectors (B).

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(2) Disconnect the Injector drive box(IDB) connector (C).

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(3) Remove the ECM (D).

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11. Disconnect the front connector (B), and then remove the wiring protector (A).

12. Remove the engine wirings from the engine room.

(1) Disconnect the junction box connector (A).
 (2) Remove the ground bolt (B).
(3) Remove the engine wirings from the engine room.

13. Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
14. Loosen the bolt & nut and then disconnect the lower arm (A) from the front knuckle.
Tightening Torque :
98.1~117.7N.m (10.0~12.0kgf.m, 72.3 ~ 86.6lb-ft)

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15. Remove the front stabilizer bar links (A).

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Tightening Torque :

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98.1~117.7N.m(10.0~12.0kgf.m, 72.3~86.8lb-ft)

16. Disconnect the tie-rod end (A) from the front knuckle.
Tightening Torque :
34.3~44.1N.m(3.5~4.5kgf.m, 25.3~32.5lb-ft)
17. Remove the drive shaft coking nut (A) from the front hub.
Tightening Torque :
240.3 ~ 269.7N.m(24.5 ~ 27.5kgf.m, 177.2 ~ 198.9lb-ft)

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18. Disconnect the driveshaft (A) from the front hub assembly.

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19. Loosen the bolt and then disconnect the universal joint assembly (A) from the pinion of the steering gear box.
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Tightening Torque:
32.4 ~ 37.3 N.m (3.3 ~ 3.8 kgf.m, 23.9 ~ 27.5 lb-ft)

20. Disconnect the heater hoses.

(Refer to Cooling System - "Heater Hose")
21. Disconnect the brake booster vacuum hose (A), the PSCV hose (B). Disconnect the and the fuel line (C).
(Refer to Fuel System - "Fuel Line")
22. Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")
23. Remove the roll road bracket (A).
Tightening Torque:
107.9 ~ 117.7 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

24. Rremove the sub frame (B).

Tightening Torque
Sub frame mounting bolts & nuts :
156.9 ~ 176.5N.m (16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
Sub frame bracket bolts & nuts :
44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

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• After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them
securely with floor jack.
• Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.

25. Disconnect the ground cable, and then remove the engine mounting bracket.
(Refer to Engine And Transmission Assembly - "Engine Mounting")
26. Disconnect the ground cable, and then remove the transaxle mounting bracket through bolt.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
27. Remove the engine and transaxle assembly by lifting vehicle.
 When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation
Installation is in the reverse order of removal.
Perform the following :
• Adjust a shift cable.
• Refill engine with engine oil.
• Refill a transaxle with fluid.
• Refill a radiator and a reservoir tank with engine coolant.
• Place a heater control knob on "HOT" position.
• Clean battery posts and cable terminals and assemble.
• Inspect for fuel leakage.
– After assemble 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.
• 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 and let it cool down. 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.
Engine Mechanical System

Components Location

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Engine Mechanical System

Removal and Installation

[Front engine hanger]
1. Remove the front engine hanger (A)
Tightening torque:
44.1 ~ 53.6N.m (4.5 ~ 5.5kgf.m, 32.5 ~ 39.8lb-ft)

2. Install in the reverse order of removal.

[Rear engine hanger]

1. Remove the rear engine hanger (A)
 Tightening torque:
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

2. Install in the reverse order of removal.

Engine Mechanical System

Components

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1. Drive belt

Engine Mechanical System

Removal and Installation

1. Disconnect the battery negative terminal.
2. To release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).

3. Installation is reverse order of removal

Engine Mechanical System

Components

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1. Idler

Engine Mechanical System

Removal and Installation

1. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
2. Remove the drive belt idler (A).
Tightening torque :
52.9 ~ 57.9N.m (5.4 ~ 5.9kgf.m, 39.1 ~ 42.7lb-ft)

3. Installation is reverse order of removal

Engine Mechanical System

Components

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1. Drive belt tensioner

 Engine Mechanical System

Removal and Installation

1. Remove the drive belt idler.
(Refer to Timing System - "Idler")
2. Remove 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)

3. Installation is reverse order of removal

Engine Mechanical System

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Components

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1. Crankshaft damper pulley

Engine Mechanical System

Removal and Installation

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Mark all wiring and hoses to avoid misconnection.

1. Remove the battery and battery tray.

(Refer to Engine Electrical System - "Battery")
2. Remove the engine cover.
3. Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
4. Remove the engine room under cover.
5. Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")
6. Remove the crankshaft damper pulley (A).
Tightening torque :
284.4 ~304.0N.m (29.0~31.0kgf.m, 209.8~224.2lb-ft)

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.

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• Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.

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1) Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")

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2) Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).

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3) Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4) Fasten the two transaxle mounting bolts in the original mounted holes.

5) Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
7. Install in the reverse order of removal.

Engine Mechanical System

Components

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1. Front oil seal

Engine Mechanical System

Removal
1. Remove the crankshaft damper pulley.
 (Refer to Timing System - "Crankshaft Damper Pulley")
2. Remove the front oil seal (A).

Installation
1. Using SST (09231-3C100), install timing chain cover oil seal.

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Always use new oil seal.

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2. Install the crankshaft damper pulley.

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(Refer to Timing System - "Crankshaft Damper Pulley")

Engine Mechanical System

Components
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1. Timing chain cover
2. Gasket

Engine Mechanical System

Removal
1. Remove the LH/RH cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
2. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
3. Remove the drive belt auto tensioner.
(Refer to Timing System - "Drive Belt Tensioner")
4. Remove the crankshaft damper pulley.
(Refer to Timing System - "Crankshaft Damper Pulley")
5. Remove the engine mounting bracket.
(Refer to Engine And Transmission Assembly - "Engine Mounting")
6. Lift up the engine assembly slightly by using a jack to get access to the side of engine.
7. Remove the water pump and gasket.
(Refer to Cooling System - "Water Pump")
8. Remove the timing chain cover (A).
 Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

Installation
1. Install the timing chain cover.
(1) 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.
(2) Before assembling the timing chain cover, the liquid sealant TB 1217H (Hyundai Gray RTV) 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.)

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(3) After applying liquid sealant TB 1217H (Hyundai Gray RTV) on timing chain cover. The part must be assembled within 5 minutes after
sealant was applied.
Sealant should be applied without discontinuity.

• Fill the T-joint area (6EA *) with sealant.

• Apply sealant all around the dowel pin hole (2EA).

(4) Install the new gasket (A) to the timing chain cover.
 During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.

(5) 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
A (17EA) :
18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
B (2EA) :
24.5 ~ 26.5N.m (2.5 ~ 2.7kgf.m, 18.1 ~ 19.5lb-ft)
C (1EA) :
58.8 ~ 68.8N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
D (1EA) :
58.8 ~ 68.8N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
E (3EA) :

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9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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(6) Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
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2. Install the front oil seal.
(Refer to Timing System - "Front Oil Seal")
3. Install the other parts reverse order of removal.

• 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 and let it cool down. 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.

Engine Mechanical System

 Components

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1. Oil pump chain cover
2. Oil pump sprocket
7. RH Timing chain auto tensioner
8. RH Timing chain tensioner arm
13. LH Timing chain tensioner arm
14. Crankshaft LH chain sprocket om
3. Oil pump chain 9. RH Timing chain 15. LH Timing chain
4. Oil pump tensioner assembly 10. RH Timing chain cam to cam guide 16. LH Timing chain cam to cam guide
5. Crankshaft oil pump sprocket 11. RH Timing chain guide 17. LH Timing chain guide
6. Crankshaft RH chain sprocket 12. LH Timing chain auto tensioner 18. Tensioner adapter

Engine Mechanical System

Removal
1. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.
 (2) Check that the mark 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°).

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Do not rotate engine counterclockwise.

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2. Remove the timing chain cover.

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(Refer to Timing System - "Timing Chain Cover")

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Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

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.
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3. Remove the oil pump chain cover (A).

4. Remove the oil pump chain tensioner assembly (A).

5. Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin into the hole on the ratchet
to hold the compressed piston.

6. Remove the RH timing chain cam to cam guide (A).

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7. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).

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8. Remove the RH timing chain guide (A).
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9. Remove the RH timing chain (A).

10. Remove the crankshaft sprocket (A) ( RH camshaft drive).

11. Remove the oil pump chain sprocket (A) and oil pump chain (B).

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12. Remove the crankshaft sprocket (A) (Oil pump drive).

13. Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin into the hole on the
ratchet to hold the compressed piston.
14. Remove the LH timing chain cam to cam guide (A).

15. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

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16. Remove the LH timing chain guide (A).

17. Remove the LH timing chain (A).

18. Remove the crankshaft sprocket (A). (LH camshaft drive).

19. Remove the tensioner adapter assembly (A).

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Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
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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.

Installation
1. Install the jack to the edge of upper oil pan to support the engine.

Insert the rubber block between jack and upper oil pan.

2.
 The key (A) of crankshaft should be aligned with the timing mark (B) of block. As a result of this, the piston of No.1 cylinder is placed at the
top dead center on compression stroke.

3. Install the tensioner adapter assembly (A).

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4. Install the crankshaft sprocket (A). (LH camshaft drive).

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5. Install the LH timing chain (A). om
 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.

6. Install the LH timing chain guide (A).

Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

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7. Install the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

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Tightening torque
A : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
B : 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

8. Install the LH timing chain cam to cam guide (A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
9. Pull out the pins of LH timing chain auto tensioner.

10. Install the crankshaft sprocket (A) (Oil pump drive).

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11. 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)

12. Install the RH timing chain (A).

 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.

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The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

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13. Install the RH timing chain guide (A).

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Tightening torque :

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A : 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

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14. Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
Tightening torque
A : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
B : 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
15. Install the RH timing chain cam to cam guide (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

16. Pull out the pins of RH timing chain auto tensioner.

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17. Install the oil pump chain tensioner assembly (A).
Tightening torque :

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9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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18. Install the oil pump chain cover (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

19. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
 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.

20. Install the timing chain cover.

(Refer to Timing System - "Timing Chain Cover")
21. Install the other parts reverse order of removal.

• 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 and let it cool down. 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.

Engine Mechanical System

Components

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1. LH cylinder head cover 4. RH cylinder head cover gasket
2. LH cylinder head cover gasket 5. Exhaust CVVT OCV cap
3. RH cylinder head cover

Engine Mechanical System

Removal
[LH]
1. Remove the Intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
2. Remove the high pressure fuel pump.
(Refer to Fuel System - "High Pressure Fuel Pump")
3. Remove the LH ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
4. Remove the front engine hanger.
(Refer to Engine And Transmission Assembly - "Engine Hanger")
5. Remove the LH cylinder head cover.
(1) Remove the LH exhaust CVVT oil control valve cap (A).
(2) Remove the LH cylinder head cover (B) and gasket.
 Cover the cylinder head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.

[RH]
1. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
2. Remove the RH ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
3. Remove the RH cylinder head cover.
(1) Remove the RH exhaust CVVT oil control valve cap (A).
(2) Remove the RH cylinder head cover (B) and gasket.

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Cover the cylinder head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
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Installation
[LH]
1. Install the LH cylinder head cover.

• 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.

(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling
cylinder head cover.
(2) After applying TB 1217H (Hyundai Gray RTV) sealant, it should be assembled within 5 minutes.
Bead width :2.5mm(0.1in.)
 (3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(4) Install the LH cylinder head cover bolts as following method.
Tightening torque :
1st step: 4.9 ~ 5.9N.m (0.5 ~ 0.6kgf.m, 3.6 ~ 4.3lb-ft)
2nd srep: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Do not reuse cylinder head cover gasket.

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(5) Install the LH exhaust CVVT oil control valve cap.

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Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Always use new exhaust CVVT oil control valve cap.

2. Install the other parts reverse order of removal.

[RH]
1. Install the RH cylinder head cover.

• 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.

(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling
cylinder head cover.
(2) After applying TB 1217H (Hyundai Gray RTV) sealant, it should be assembled within 5 minutes.
Bead width :2.5mm(0.1in.)
 (3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(4) Install the RH cylinder head cover bolts as following method.
Tightening torque :
1st step: 4.9 ~ 5.9N.m (0.5 ~ 0.6kgf.m, 3.6 ~ 4.3lb-ft)
2nd srep: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Do not reuse cylinder head cover gasket.

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(5) Install the RH exhaust CVVT oil control valve cap.

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Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Always use new exhaust CVVT oil control valve cap.

2. Install the other parts reverse order of removal.

Engine Mechanical System

Components
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1. RH exhaust CVVT 3. LH intake CVVT
2. RH intake CVVT 4. LH exhaust CVVT

Engine Mechanical System

Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with the
ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC). CVVT
improves engine performance through reduction of pump loss, internal EGR effect, improvement of combustion stability, improvement of
volumetric efficiency, and increase of expansion work.
This system consist of
– the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or runs out the engine oil from the cam phaser in
accordance with the ECM PWM (Pulse With Modulation) control signal,
– the CVVT Oil Temperature Sensor (OTS) which measures the engine oil temperature,
– and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil released out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite
direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.
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Operation Principle
The CVVT has the mechanism rotating the rotor vane with hydraulic force generated by the engine oil supplied to the advance or retard

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chamber in accordance with the CVVT oil control valve control.

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 [CVVT System Mode]

(1) Low Speed / Low Load (2) Part Load

(3) Low Speed / High Load (4) High Speed / High Load

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Exhaust Valve Intake Valve
Driving
Valve Valve
Condition Effect Effect
Timing Timing
(1) Low Speed Completely * Valve Under-lap Completely * Valve Under-lap
/Low Load Advance * Improvement of combustion stability Retard * Improvement of combustion stability
* Increase of expansion work
(2) Part Load Retard * Reduction of pumping loss Retard * Reduction of pumping loss
* Reduction of HC
(3) Low Speed * Prevention of intake back flow (Improvement
Retard * Increase of expansion work Advance
/High Load of volumetric efficiency)
(4) High Speed
Advance * Reduction of pumping loss Retard * Improvement of volumetric efficiency
/High Load

Engine Mechanical System

Removal
1. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2. Remove the CVVT assembly.
• A: LH exhaust CVVT
• B: LH intake CVVT
 • C: RH intake CVVT
• D: RH exhaust CVVT

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When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.

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Inspection
1. Inspect the CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.

[Intake]
 [Exhaust]

(3) Wrap tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port of the camshaft.
(Perform this in order to release the lock pin for the maximum delay angle locking.)

When the oil splashes, wipe it off with a shop rag.

(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your
hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand.

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(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the
movable range and that there is no interference.
Standard:Movable smoothly in the range about 25°

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (clockwise).

Installation
1. Install the CVVT assembly.
Tightening torque :
64.7 ~ 76.5N.m (6.6 ~ 7.8kgf.m, 47.7 ~ 56.4lb-ft)

• Install camshaft-inlet to dowel pin of CVVT assembly.

At this time, attend not to be installed to oil hole of camshaft-inlet.
• Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
 • Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.

• A: LH exhaust CVVT
• B: LH intake CVVT

• C: RH intake CVVT
• D: RH exhaust CVVT

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When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.

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2. Install the timing chain.

(Refer to Timing System - "Timing Chain")

Engine Mechanical System

Components
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1. RH exhaust camshaft 3. LH intake camshaft
2. RH intake camshaft 4. LH exhaust camshaft

Engine Mechanical System

Removal
[RH]
1. Remove the RH bank timing chain.
(Refer to Timing System - "Timing Chain")
2. Remove the RH exhaust CVVT oil control valve.
(Refer to Fuel System - "CVVT Oil Control Valve(OCV)"
3. Remove the RH camshaft bearing cap (A) and thrust bearing cap (B).
4. Remove the RH intake camshaft (A) and exhaust camshaft (B)

[LH]
1. Remove the RH/LH timing chain.

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(Refer to Timing System - "Timing Chain")

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2. Remove the LH exhaust CVVT oil control valve.
(Refer to Fuel System - "CVVT Oil Control Valve(OCV)"

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3. Remove the fuel pump bracket (A)

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4. Remove the LH camshaft bearing cap (A) and thrust bearing cap (B).

5. Remove the LH intake camshaft (A) and exhaust camshaft (B)

 Installation

• Apply a light coat of engine oil on camshaft journals.

• Assemble the key groove of camshaft rear side to the same level of head top surface.
• Be careful the right, left bank, intake, exhaust side before assembling.

[RH]
1. Install the RH intake camshaft (A) and exhaust camshaft (B)

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RH Inkate camshaft

As for camshaft identification, refer to the table below.

Outer diameter
A 30mm (1.1811in.)
B 27mm (1.0630in.)
C 30mm (1.1811in.)
D 30mm (1.1811in.)
E 30mm (1.1811in.)

RH Exhaust camshaft
 As for camshaft identification, refer to the table below.
Outer diameter
A 27mm (1.0630in.)
B 27mm (1.0630in.)
C 30mm (1.1811in.)
D 30mm (1.1811in.)

2. Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.

Be careful the right, left bank, intake, exhaust side before assembling.

A : L(LH),R(RH)
B : I(Intake), None(Exhaust)
C : Journal number
D : Front mark
 Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.) from the top of cylinder
block.

3. Install the other parts reverse order of removal.

[LH]
1. Install the LH intake camshaft (A) and exhaust camshaft (B)

LH Inkate camshaft

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As for camshaft identification, refer to the table below.

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Outer diameter

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A -
B -
C -
D -
E -

The LH intake camshaft dosen''t have identification ring.

LH Exhaust camshaft

As for camshaft identification, refer to the table below.

Outer diameter
A 27mm (1.0630in.)
 B 27mm (1.0630in.)
C 30mm (1.1811in.)
D 27mm (1.0630in.)

2. Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.

Be careful the right, left bank, intake, exhaust side before assembling.

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A : L(LH),R(RH)
B : I(Intake), None(Exhaust) om
C : Journal number
D : Front mark

Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.) from the top of cylinder
block.

3. Install the fuel pump bracket (A)

Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
4. Install the other parts reverse order of removal.

Engine Mechanical System

Components

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1. RH Cylinder head 4. LH Cylinder head gasket

2. RH Cylinder head gasket 5. Cylinder block
3. LH Cylinder head
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1. Camshaft bearing cap 9. Retainer 17. LH Intake camshaft OCV
2. Camshaft thrust bearing cap 10. Valve spring 18. Fuel pump bracket
3. RH Exhaust camshaft 11. Valve stem seal 19. LH Intake camshaft
4. RH Intake camshaft 12. Valve 20. LH Exhaust camshaft
5. RH Exhaust CVVT assembly 13. RH Intake camshaft OCV 21. LH Intake CVVT assembly
6. RH Intake CVVT assembly 14. RH Exhaust camshaft OCV 22. LH Intake CVVT assembly
7. Mechanical lash adjuster (MLA) 15. RH Cylinder head 23. LH Cylinder head
8. Retainer lock 16. LH Exhaust camshaft OCV

Engine Mechanical System

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F])
before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

 • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

[RH]
1. Remove the RH camshafts.
(Refer to Cylinder Head Assembly - "Camshaft")
2. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
3. Remove the RH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
4. Remove the RH cylinder head.
(1) Remove the RH cylinder head rear bolt (A).

(2) Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

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Head warpage or cracking could result from removing bolts in an incorrect order.
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(3) Lift the RH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

(4) Remove the RH cylinder head gasket.

[LH]
1. Remove the LH camshafts.
(Refer to Cylinder Head Assembly - "Camshaft")
2. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
3. Remove the LH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
4. Remove the LH cylinder head.
(1) Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

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Head warpage or cracking could result from removing bolts in an incorrect order.

(2) Lift the LH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

(3) Remove the LH cylinder head gasket.

 Disassembly

Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original position.

1. Remove the MLAs (A).

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2. Remove the valves.

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(1) Using the SST (09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

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(2) Remove the spring retainer.

(3) Remove the valve spring.
(4) Remove the valve.
(5) Using the SST (09222-29000), remove the valve stem seal.
 Do not reuse old valve stem seals.

3. Remove the LH/RH intake camshaft OCV (A).

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Inspection

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Cylinder Head
1. Inspect for flatness.

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Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.

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Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in.)
[Less than 0.02mm(0.0008in.)/150x150]
Flatness of manifold gasket surface
Standard : Less than 0.03mm(0.001in)/110x110

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

Valve And Valve Spring

1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)
 (2) Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

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(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

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Valve stem-to-guide clearance

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[Standard]

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Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)

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[Limit]
Intake : 0.07mm (0.0027in.)

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Exhaust : 0.09mm (0.0035in.)

2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.)

(4) Check the valve length.

Length
 Intake : 105.27mm (4.1445in)
Exhaust : 105.50mm (4.1535in)

(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.

3. Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head. Recondition the valve seat
with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 45.5mm (1.7913in.)
Out-of-square : 1.5°

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MLA

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1. Inspect MLAs.

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Using a micrometer, measure the MLA outside diameter.

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MLA O.D.
Intake/Exhaust :
34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)

2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust :
35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)

3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)

Camshaft
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 46.6mm (1.835in.)
Exhaust : 45.8mm (1.8031in.)
 If the cam lobe height is less than standard, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.

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(4) Install the bearing cap (A) and thrust bearing cap (B) with specified torque. (Refer to Cylinder head)

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Tightening torque :

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1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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Do not turn the camshaft.

 (5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.027 ~ 0.057mm (0.0010 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.

3. Inspect the camshaft end play.

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(1) Install the camshafts.

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(2) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :

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1st step : 5.8N.m (0.6kgf.m, 4.31lb-ft)

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2st step : 9.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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(3) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)
 If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(4) Remove the camshafts.

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Reassembly

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Thoroughly clean all parts to be assembled.

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Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

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1. Install the valves.

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(1) Using the SST (09222-3C100), push in a new oil seal.

Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.

(2) Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer.

(3) Using the SST (09222 - 3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure
that the retainer locks are correctly in place before releasing the valve spring compressor.
 (4) Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper
seating of the valve and retainer lock.

2. Install the MLAs.

Check that the MLA rotates smoothly by hand.

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MLA can be reinstalled in its original position.

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However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the
cylinder block.

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Refer to General information in EM section for Valve Clearance checking and adjustment procedure.

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3. Install the LH/RH inteke camshaft CVVT OCV(A).
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
 • Install OCV with gray colored connector into RH bank.
• Install OCV with black colored connector into LH bank.

• Do not reuse the OCV when dropped.

• Keep the OCV clean.
• Do not hold the OCV sleeve during servicing.
• When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

Installation

• Thoroughly clean all parts to be assembled.

• Always use a new head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotate the crankshaft, set the No.1 piston at TDC.

[RH]
1. Install the cylinder RH head.
a. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
b. Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.

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Refer to below illustration to apply the sealant.

Bead width :
2.0~3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0~1.5mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant :TB 1217H (Hyundai Gray RTV) Liquid sealant
c. Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

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Be careful of the installation direction.

d. Install the RH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

2. Install the RH cylinder head bolts.
(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

Always use a new cylinder head bolts.

Tightening torque
Head bolt: 37.3~41.2N.m (3.8~4.2kgf.m, 27.5~30.4lb-ft) + (118~122°) + (88~92°)
Bolt (A):18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

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3. Install the other parts reverse order of removal.

 • 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 and let it cool down. 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.

[LH]
1. Install the cylinder LH head.
a. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
b. Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.

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Refer to below illustration to apply the sealant.

Bead width :
2.0~3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0~1.5mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant :TB 1217H (Hyundai Gray RTV) Liquid sealant

c. Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
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Be careful of the installation direction.

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d. Install the LH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

2. Install the LH cylinder head bolts.

(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
 (2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

Always use a new cylinder head bolts.

Tightening torque
Head bolt: 37.3~41.2N.m (3.8~4.2kgf.m, 27.5~30.4lb-ft) + (118~122°) + (88~92°)

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3. Install the other parts reverse order of removal.

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• 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 and let it cool down. 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.

Engine Mechanical System

Components
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1. Water jacket separator om
Engine Mechanical System

Removal
1. Remove the LH/RH cylinder head assembly and gasket.
(Refer to Cylinder Head Assembly - "Cylinder Head")
2. Remove the water jacket seperator (A).

Installation
1. Install the #1, #2 cylinder bore water jacket seperator (A).

Insert the seperator align with block inner side protrusion, and it must be located under the cylinder head installing surface.

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2. Install the LH/RH cylinder head assembly and gasket.
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(Refer to Cylinder Head Assembly - "Cylinder Head")

Engine Mechanical System

Components
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1. Drive plate
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2. Adapter plate

Engine Mechanical System

Removal and Installation

1. Remove the automatic transaxle.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
2. Remove the adapter plate (B) and the drive plate (A).
Tightening torque :
71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)
3. Install in the reverse order of removal.

Engine Mechanical System

Components

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1. Rear oil seal

2. Oil seal case

Engine Mechanical System

Removal
1. Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
2. Remove the rear oil seal (A).
 Installation
1. Using SST (09231-3C200, 09231-H1100), install the rear oil seal.

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Always use new oil seal.

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2. Install the drive plate.

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(Refer to Cylinder Block - "Drive Plate")

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Engine Mechanical System

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Components
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1. Piston ring
2. Piston
5. Piston pin
6. Connecting rod lower bearing
9. Upper oil pan
10. Cylinder block
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3. Connecting rod 7. Connecting rod bearing cap 11. Snap ring
4. Connecting rod upper bearing 8. Baffle plate 12. Water jacket separator
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1. Oil drain cover 5. Adapter plate 9. Crankshaft
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2. Oil drain cover gasket 6. Drive plate 10. Crankshaft lower bearing
3. Crank shaft upper bearing 7. Rear oil seal 11. Main bearing cap
4. Thrust bearing 8. Rear oil seal case 12. Oil cover
13. Oil cover gasket

Engine Mechanical System

Disassembly

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• Mark all wiring and hoses to avoid misconnection.

• Inspect the timing chain before removing the cylinder head.
• Turn the crankshaft pulley so that the No.1 piston is at top dead center.
• Engine removal is required for this procedure.

1. Remove the engine assembly from the vehicle.

 (Refer to Engine And Transmission Assembly - "Engine And Transmission Assembly")
2. Attach the engine to engine stand for disassembly.
3. Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
4. Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
5. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
6. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Aassembly")
7. Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
8. Remove the water jacket seperator.
(Refer to Cylinder Block - "Water Jacket Seperator")
9. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10. Remove the oil filter assembly.
(Refer to Lubrication System - "Oil Filter")
11. Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
12. Remove the oil cover (A) and gasket (B).

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13. Remove the knock sensor (A).

14. Remove the upper oil pan (A).

15. Remove the baffle plate (A).

16. Remove the rear oil seal case (A).

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17. Remove the oil drain cover (A) and gasket (B).

18. Check the connecting rod end play.

19. Check the connecting rod cap oil clearance.
20. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.

•
 Arrange the piston and connecting rod assemblies in the correct order.

21. Remove the crankshaft main bearing cap and check oil clearance.
22. Check the crankshaft end play.
23. Lift the crankshaft (A) out of engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.

24. Remove the oil jets (A).

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25. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove 2 side rails and the spacer by hand.

Arrange the piston rings in the correct order only.

26. Disconnect the connecting rod from the piston.

Remove the snap ring at both ends of piston pin. And push the piston pin to seperate and connecting rod.

Inspection
Connecting Rod And Crankshaft
1. Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play :0.1~ 0.25mm(0.004 ~ 0.010in.)
 • If out-of-tolerance, install a new connecting rod.
• If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and bearing half.
(4) Clean the crank pin and bearing.
(5) Place plastigage across the crank pin.
(6) Reinstall the bearing half and cap, and torque the bolts.
Tightening torque:
27.5~31.4N.m (2.8~3.2kgf.m, 20.3~23.1lb-ft) + (68~72°)

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Do not turn the crankshaft.

(7) Remove 2 bolts, connecting rod cap and bearing half.

(8) Measure the plastigage at its widest point.
Standard oil clearance:
0.044 ~ 0.062mm(0.0017 ~ 0.0024in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same
color mark (select the color as shown in the next column), and recheck the clearance.
 Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one),
and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start
over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting Rod Mark Location

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Identification Of Connecting Rod

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Class Mark Inside Diameter
58.000 ~ 58.006mm

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0 a
(2.2834 ~ 2.2837in.)

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58.006 ~ 58.012mm
1 b
(2.2837 ~ 2.2839in.)

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58.012 ~ 58.018mm

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2 c
(2.2839 ~ 2.2842in.)

Crankshaft Pin Mark Location

Identification Of Crankshaft

Discrimination Of Crankshaft
Class Mark Outside Diameter Of Pin
54.966 ~ 54.972mm
I 1 or A
(2.1640 ~ 2.1642in.)
54.960 ~ 54.966mm
II 2 or B
(2.1638 ~ 2.1640in.)
54.954 ~ 54.960mm
III 3 or C
(2.1635 ~ 2.1638in.)
 Place Of Identification Mark (Connecting Rod Bearing)

Identification Of Connecting Rod Bearing

Class Mark Thickness Of Bearing
1.511 ~ 1.514mm
E Blue
(0.0595 ~ 0.0597in.)
1.508 ~ 1.511mm
D Black
(0.0594 ~ 0.0595in.)
1.505 ~ 1.508mm
C Red
(0.0593 ~ 0.0594in.)
1.502 ~ 1.505mm
B Green
(0.0591 ~ 0.0593in.)
1.499 ~ 1.502mm
A Yellow

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(0.0590 ~ 0.0591in.)

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(11) Selection

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Connecting Rod Identification Mark

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0(a) 1(b) 2(c)
A B C

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1 or A
(Yellow) (Green) (Red)

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Crankshaft Indentification B C D
2 or B
Mark (Green) (Red) (Black)
C D E
3 or C
(Red) (Black) (Blue)

3. Check the connecting rod.

(1) When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches
for bearing fixing on the connecting rods and caps should face the same direction.
(2) If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or
rough, also replace it.
(3) Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with
a press. If the rod is bent or twisted excessily, replace it.
Allowable bend of connecting rod
0.05mm/100mm (0.0020in./3.9370in.)
Allowable twist of connecting rod
0.1mm/100mm (0.0039in./3.9370in.)

When assembling the rod without a bearing, there should be no differance.

4. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
 Tightening torque:
49.0Nm(5.0 kgf.m, 36.2lb-ft) + 90°
19.6Nm(2.0 kgf.m, 14.5lb-ft)+ 120°
29.4 ~ 31.4Nm(3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1lb-ft)

Do not turn the crankshaft.

(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance:
0.022 ~ 0.040mm (0.0009 ~ 0.0016in.)

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(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same
color mark (select the color as shown in the next column), and recheck the clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one),
and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start
over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Crankshaft bore mark location

Letters have been stamped on the block as a mark for the size of each of the 4 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Discrimination Of Cylinder Block
Class Mark Inside Diameter
73.500 ~ 73.506mm
a A
(2.8937 ~ 2.8939in.)
73.506 ~ 73.512mm
b B
(2.8939 ~ 2.8942in.)
73.512 ~ 73.518mm
c C
(2.8942 ~ 2.8944in.)

Crankshaft Journal Mark Location

Discrimination Of Crankshaft

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Discrimination Of Crankshaft
Class Mark Outside Diameter Of Journal
68.954 ~ 68.960mm
I 1 or A
(2.7147 ~ 2.7150in.)
68.948 ~ 68.954mm
II 2 or B
(2.7145 ~ 2.7147in.)
68.942 ~ 68.948mm
III 3 or C
(2.7142 ~ 2.7145in.)

Place Of Identification Mark (Crankshaft Bearing)

 Discrimination Of Crankshaft Bearing
Class Mark Thickness Of Bearing
2.277 ~ 2.280mm
E Blue
(0.0896 ~ 0.0897in.)
2.274 ~ 2.277mm
D Black
(0.0895 ~ 0.0896in.)
2.271 ~ 2.274mm
C Red
(0.0894 ~ 0.0895in.)
2.268 ~ 2.271mm
B Green
(0.0893 ~ 0.0894in.)
2.265 ~ 2.268mm
A Yellow
(0.0892 ~ 0.0893in.)

Selection
Crankshaft Bore Identification Mark
a(A) b(B) c(C)
A B C
1 or A
(Yellow) (Green) (Red)
Crankshaft Identification B C D
2 or B
Mark (Green) (Red) (Black)
C D E
3 or C
(Red) (Black) (Blue)

5. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

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Standard end play :

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0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

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If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness :
2.41 ~ 2.45mm(0.0949 ~ 0.0964in.)

6. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Crank pin diameter :
54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)
Cylinder Block
1. Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of the cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05mm(0.0020 in.),
Less than 0.02mm(0.0008in.) / 150 x 150

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4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratchs.
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If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter :
92.00 ~ 92.03mm (3.6220 ~ 3.6232in.)

6. Check the cylinder bore size code on the cylinder block.

 Class Size code Cylinder bore inner diameter
92.00 ~ 92.01mm
A A
(3.6220 ~ 3.6224in.)
92.01 ~ 92.02mm
B B
(3.6224 ~ 3.6228in.)
92.02 ~ 92.03mm
C C
(3.6228 ~ 3.6232in.)

7. Check the piston size code (A) and the front mark (B) on the piston top face.

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Class Size code Piston outer diameter

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91.96 ~ 91.97mm
A A
(3.6204 ~ 3.6208in.)
91.97 ~ 91.98mm
B B
(3.6208 ~ 3.6212in.)
91.98 ~ 91.99mm
C C
(3.6212 ~ 3.6216in.)

8. Select the piston related to cylinder bore class.

Clearance :0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

Boring Cylinder
1. Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark Size
0.1 0.1 mm (0.004 in)
0.25 0.25 mm (0.010 in)

The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D(Outer Diameter), calculate the new bore size.
New bore size = piston O.D + 0.03 to 0.05mm (0.0012 to 0.0020in) (clearance between piston and cylinder) -
0.01mm (0.0004in) (honing margin.)

4. Bore each of the cylinders to the calculated size.

 To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard :0.03 ~ 0.05mm (0.0012 ~ 0.0020in)

When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.

Piston And Rings

1. Clean piston
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 12 mm (0.4724 in.) from the bottom of the piston.
Standard diameter :
91.96 ~ 91.99mm (3.6204 ~ 3.6216in.)

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3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance:
0.03 ~ 0.05mm (0.0012 ~ 0.0020in.)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.)
No.2 : 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.)
Oil ring : 0.02 ~ 0.06mm (0.0008 ~ 0.0024in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
 If the clearance is greater than maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently
pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap
is too large, recheck the cylinder bore diameter against the wear limits. If the bore is over the service limit, the cylinder block must be
replaced.
Piston ring end gap
Standard
No.1 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)
No.2 : 0.37 ~ 0.52mm (0.0145 ~ 0.0204in.)
Oil ring : 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

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Piston Pins
1. Measure the diameter of the piston pin.
Piston pin diameter:
21.097 ~ 22.000mm (0.8305 ~ 0.8661in.)
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance:
0.004 ~ 0.013mm (0.00015~ 0.00051in.)

3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference:
0.005 ~ 0.019mm (0.00019 ~ 0.00074in.)

Reassembly

• Thoroughly clean all parts to be assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble the piston and the connecting rod.

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(1) Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly.

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(2) The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.

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2. Install the piston rings.
(1) Install the coil spring and oil ring by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.

(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2) Install the bearings (A) in the connecting rod and connecting rod cap (B).
 When reassembling the connecting rods and the caps, ensure te front marks on then and the number of cylinder.

4. Install the oil jets (A).

Tightening torque:
27.5 ~ 31.3 N.m (2.8 ~ 3.2kgf.m, 20.2 ~ 23.1lb-ft)

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5. Install the main bearings.

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Upper bearings have an oil groove of oil holes; Lower bearings do not.

(1) Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A).

(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

6. Install the thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
7. Place the crankshaft (A) on the cylinder block.

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8. Place the main bearing caps on cylinder block.

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9. Install the main bearing cap bolts.

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(1) Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.
Tightening torque

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Main bearing cap bolt

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49.0N.m (5.0 kgf.m, 36.2lb-ft) + 90° (1 ~ 8)
19.6N.m (2.0 kgf.m, 14.5lb-ft) + 120° (9 ~ 16)
29.4 ~ 31.4N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1lb-ft) (17 ~ 24)

• Always use new main bearing cap bolts.

• If any of the bearing cap bolts are broken or deformed, replace it.

Use the SST (09221-4A000), install main bearing cap bolts.

 (2) Check that the crankshaft turns smoothly.

10. Check crankshaft end play.

11. Install the piston and connecting rod assemblies.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.

(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the
wooden handle of a hammer.
(2) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into
place.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque:
27.5~31.4N.m (2.8~3.2kgf.m, 20.3~23.1lb-ft) + (68~72°)

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• Always use new connecting rod bearing cap bolts.

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• Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.

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Use SST (09221-4A000), install connecting rod bearing cap bolts.

12. Check the connecting rod end play.

13. Install the oil drain cover (A) with a new gasket (B).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

14. Install the rear oil seal case(A).

Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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• Clean the sealing face before assembling two parts.

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• Remove harmful foreign materials on the sealing face before applying sealant

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• Before assembling rear oil seal case, the liquid sealant TB1217H should be applied to the rear oil seal case.
• The part must be assembled within 5 minutes after sealant was applied.
• Apply sealant to the inner threads of the bolt holes.

15. Iinstall the rear oil seal.

(Refer to Cylinder Block - "Rear Oil Seal")
16. Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
17. Install the upper oil pan.
(Refer to Lubrication System - "Oil Pan")
18. Install the oil cover (A) and gasket (B).
Tightening torque:
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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19. Install the knock sensor (A).

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Tightening torque:

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15.7 ~ 23.5Nm (1.6 ~ 2.4kgf.m, 11.6 ~ 17.3lb-ft)

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20. Install the drive plate.

(Refer to Cylinder Block - "Drive Plate")
21. Install the oil filter assembly.
(Refer to Lubrication System - "Oil Filter")
22. Install the oil pump.
(Refer to Lubrication System - "Oil Pump")
23. Install the water jacket seperator.
(Refer to Cylinder Block - "Water Jacket Seperator")
24. Install the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
25. Install the water temperature control assembly.
(Refer to Engine Mechanical System - "Water Temperature Control Aassembly")
26. Install the timing chain.
(Refer to Timing System - "Timing Chain")
27. Install the exhaust manifold.
 (Refer to Intake And Exhaust System - "Exhaust Manifold")
28. Install the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
29. Install the engine assembly to the vehicle.
(Refer to Engine And Transmission Assembly - "Engine And Transmission Assembly")

Engine Mechanical System

Replacement And Air Bleeding

Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from
the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any
coolant spills, rinse it off immediately.

1. Make sure the engine and radiator are cool to the touch.
2. Remove the radiator cap (A).

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3. Remove the engine room under cover.

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4. Loosen the drain plug (A), and drain the coolant.

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5. Tighten the radiator drain plug securely.

6. Remove, drain and reinstall the reservoir.
(Refer to Cooling System - "Reservoir Tank")
Fill the tank halfway to the F mark with water, then up to the F mark with antifreeze.
7. Fill the radiator with water through the radiator cap and tighten the cap.

To most effectively bleed the air, pour the water slowly and press on the upper / lower radiator hoses.

8. Start the engine and allow to come to normal operating temperature. Wait for the cooling fans to turn on several times. Accelerate the
engine to aid in purging trapped air. Shut engine off.
9. Wait until the engine is cool.
10. Repeat steps 1 to 8 until the drained water runs clear.
11. Fill fluid mixture with coolant and water(5 : 5) (Tropical region – 4:6) slowly through the radiator cap. Push the upper/lower hoses of the
radiator so as bleed air easily.

• Use only genuine antifreeze/coolant.

• For best corrosion protection, the coolant concentration must be maintained year-round at 35% minimum. Coolant
concentrations less than 35% may not provide sufficient protection against corrosion or freezing.
• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

• Do not mix different brands of antifreeze/coolants.

• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.

12. Start the engine and run coolant circulates.

13. When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
14. Repeat step.11 until the cooling fan 3 ~ 5times and bleed air sufficiently out of the cooling system.
15. Install the radiator cap and fill the reservoir tank to the "F" line with coolant.
16. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
17. Stop the engine and wait coolant gets cool.
18. Repeat 10 to 15 until the coolant level doesn''t fall any more, bleed air out of the cooling system.

As it is to bleed air out to the cooling system and refill coolant when coolant gets cool completely, recheck the coolant level in the
reservoir tank for 2 ~ 3 days after replacing coolant.

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Coolant capacity :
8.4L(8.87US qt, 7.38lmp qt, 2.21US.gal)

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Engine Mechanical System

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Components

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1. Heater hose (Inlet)

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2. Heater hose (Outlet)

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3. Clamp

Engine Mechanical System

Removal and Installation

1. Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
2. Drain the coolant.
(Refer to Cooling System - "Coolant")
3. Remove the heater hoses (A).

When installing the heater hoses, install as shown in illustrations.

4. Installation is reverse order of removal

Engine Mechanical System

Components

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1. Radiator upper hose
2. Radiator lower hose
3. Hose clip
4. Clamp om
Engine Mechanical System

Removal and Installation

1. Remove the battery and tray.
(Refer to Engine Electrical System - "Battery")
2. Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
3. Drain the coolant.
(Refer to Cooling System - "Coolant")
4. Loosen the upper hose clip fixing bolt (A), and then remove the radiator upper hose (B) and lower hose (C).
Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
 When installing radiator hoses, install as shown in illustrations.

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5. Installation is reverse order of removal

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Engine Mechanical System

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Components

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1. Cooling fan
2. Fan motor
3. Fan shroud
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Engine Mechanical System

Removal and Installation

1. Remove the battery and tray.
(Refer to Engine Electrical System - "Battery")
2. Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
3. Loosen the upper hose fixing bolt (A), and disconnect the fan motor connector (B).
 The radiator hoses are still connected.

4. Remove cooling fan assembly (A).

Tightening torque :
3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

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5. Installation is reverse order of removal

Engine Mechanical System

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Components
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1. Radiator
2. Radiator mounting bracket
3. Radiator cap
4. Drain plug
5. Mounting insulator om
Engine Mechanical System

Removal and Installation

1. Remove the radiator upper hose and lower hose.
(Refer to Cooling System - "Radiator Hose")
2. Remove the cooling fan assembly.
(Refer to Cooling System - "Cooling Fan")
3. Disconnect the ATF cooler hoses.
(Refer to Automatic Transaxle System - "Automatic transaxle")
4. Disconnect the over flow hose.
(Refer to Cooling System - "Reservoir Tank")
5. Remove the radiator mounting brackets (A).
Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
6. Separate the condenser from the radiator and then pull radiator (A) up and remove it from engine room.

7. Installation is in the reverse order of removal.

8. Fill the radiator with coolant and check for leaks.

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• Bleed air from the cooling system.

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– Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)

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– Turn off engine and let it cool down. Check the coolant level and add coolant if needed. This will allow trapped air to be removed
from the cooling system.

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– Put the radiator cap on tightly, then run engine again and check for leaks.

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Inspection
Radiator Cap Testing
1. Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester.

2. Apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

Radiator Leakage Test

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure
tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kpa (0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi).
3. Inspect for engine coolant leaks and a drop in pressure.
4. Remove the tester and reinstall the radiator cap.

Check for engine oil in the coolant and/or coolant in the engine oil.

Engine Mechanical System

Components

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1. Reservoir tank
2. Over flow hose

Engine Mechanical System

Removal and Installation

1. Disconnect the over flow hose (A), and then remove the resorvior tank (B).
Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
2. Installation is in the reverse order of removal.
3. Fill the reservoir tank to the "F" line with coolant.

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Engine Mechanical System

Components

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1. Water temperature control assembly
2. Throttle body water hose
3. Gasket

Engine Mechanical System

Removal and Installation

1. Remove the radiator upper hose and lower hose.
(Refer to Cooling System - "Radiator Hose")
2. Disconnect the throttle body water hoses.
(Refer to Fuel System - "ETC (Electronic Throttle Control) System")
3. Disconnect the heater hoses.
(Refer to Cooling System - "Heater Hose")
4. Disconnect the WTS & gauge unit connector (A)
5. Separate the engine wiring protector mounted on the water temperature control assembly.

When installing, be sure to install the wiring protector mounting bolts of the original.
If other bolts(longer or larger) has been installed, this can damage the water temperature control assembly and coolant may be leak.

6. Remove the water temperature control assembly (A) and the gaskets.
Tightening torque:
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

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When installing, install the gasket with new one.

7. Install in the reverse order of removal.

Engine Mechanical System

Components
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1. Water center pipe
2. O-ring

Engine Mechanical System

Removal and Installation

1. Remove the delivery pipe and injector assembly.
(Refer to Fuel System - "Delivery Pipe")
2. Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
3. Remove the water center pipe (A).
Tightening torque:
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
 Do not reuse water pipe O-ring.

4. Installation is in the reverse order of removal.

Engine Mechanical System

Components

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1. Water pump pulley

2. Water pump
3. Water pump gasket
 Engine Mechanical System

Removal
1. Drain the coolant.
(Refer to Cooling System - "Coolant")
2. Remove the drive belt.
(Refer to Timing System - "Drive Belt")
3. Remove the water pump pulley (A).

4. Remove the water pump (A) and gaskets (B).

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Installation
Water Pump
1. Install the water pump (A) with the new gaskets (B).
 • Clean the contact face before assemble.

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• Always use a new gaskets.

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Tightening torque
A(3EA): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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B(1EA): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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C(1EA): 21.6 ~ 26.5N.m (2.2 ~ 2.7kgf.m, 15.9 ~ 19.5lb-ft)
D(1EA): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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E(1EA): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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F(1EA): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
G(4EA) :21.6 ~ 23.5N.m (2.2 ~ 2.4kgf.m, 15.9 ~ 17.4lb-ft)

2. Install the water pump pulley (A).

Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
3. Install the drive belt.
(Refer to Timing System - "Drive Belt")
4. Fill the radiator with coolant and check for leaks.

Engine Mechanical System

Troubleshooting
Symptoms Possible Causes Remedy
Coolant leakage • From the bleed hole of Visually check • Check leaks after about ten- • If coolant still leaks, replace a water
the water pump minute warming up. pump.
• If leakage stops, reuse the water
pump (Do not replace the pump with
a new one).
• From gaskets or bolts • Check the tightening of the • Retighten the mounting bolts.
water pump mounting bolts.
• Check damage of gaskets or • Replace the gasket and clean dust

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inflow of dust. off.
• From outer surface of • Check the material or any • Poor material. If any crack found,

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water pump cracks of the water pump. replace the water pump.

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Noise • From bearings Inspection with a • After starting the engine, • If there is no noise, reuse the water
• From mechanical seals stethoscope check noise with a pump(do not replace it).

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• Impeller interference stethoscope. • If there is any noise from the water
pump, remove the drive belt and

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recheck.

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Inspection after • After removing a water pump • If there is noise, reuse the water
removing a drive belt and a drive belt, check noise pump. Check other drive line parts.
again. • If there is no noise, replace the
water pump with a new one.
Inspection after • After removing a water pump • If there is any interference between
removing a water pump and a drive belt, check noise them, replace the water pump with a
again. new one.
Overheating • Damaged impeller Loosened impeller • Corrosion of the impeller wing • Check engine coolant.
• Loosened impeller • Poor coolant quality / Maintenance
check
• Impeller seperation from the • Replace the water pump.
shaft

Engine Mechanical System

Components
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1. Water temperature control assembly
2. Thermostat
3. Water inlet fitting

Engine Mechanical System

Removal

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even
if the engine tends to overheat.

1. Drain engine coolant so its level is below thermostat.

(Refer to Cooling System - "Coolant")
2. Remove the ratiator upper hose.
(Refer to Cooling System - "Radiator Hose")
3. Remove the water inlet fitting (A) and the thermostat (B).
 Inspection
1. Immerse the thermostat in water and gradually heat the water.

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2. Check the valve opening temperature.
Valve opening temperature:

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88±2°C (109.4±3.6°F)

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Full opening temperature:100°C (212°F)

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If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.

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Valve lift :10mm (0.3937in.) or more at 95°C (203°F)

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If the valve lift is not as specified, replace the thermostat.

Installation
1. Place the thermostat in thermostat housing.
(1) Install the thermostat with the jiggle valve upward.
(2) Install a new thermostat (B).

2. Install the water inlet fitting (A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

3. Install the ratiator upper hose.

(Refer to Cooling System - "Radiator Hose")
4. Fill with engine coolant.
5. Start engine and check for leaks.
 Engine Mechanical System

Troubleshooting
Symptoms Possible Causes Remedy
Coolant leakage • From the thermostat Check the mounting • Check the torque of the • Retighten the bolts and check
gasket bolts mounting bolts leakage again.
Check the gasket for • Check gasket or seal for • Replace gaskets and reuse the
damage damage thermostat.
Cooled • Low heater performance Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
excessively (cool air blowed-out) removing the radiator
• Thermogauge indicates cap.
''LOW'' GDS check & Starting • Check DTCs • Check the engine coolant
engine • Check connection of the fan sensor, wiring and connectors.
clutch or the fan motor. • Replace the componants.
※ If the fan clutch is always
connected, there will be a noise at
idle.
Remove the thermostat • Check if there are dusts or • Clean the thermostat valve and
and inspect chips in the thermostat valve. reuse the thermostat.
• Check adherence of the • Replace the thermostat, if it
thermostat. doesn''t work properly.
Heated • Engine overheated Visually check after • Insufficient coolant or leakage. • After refilling coolant, recheck.
excessively • Thermogauge indicates removing the radiator ※ Be careful when removing a • Check the cylinder head
''HI'' cap. radiator cap of the overheated gaskets for damage and the
vehicle. tightening torque of the
• Check air in cooling system. mounting bolts.
GDS check & Starting • Check DTCs • Check the engine coolant
engine • Check the fan motor sensor, wiring and connectors.
performance as temperature • Check the fan motor, the relay
varies. and the connector.

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• Check if the fan clutch slips. • Replace the fan clutch, if it
doesn''t work properly.

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• Check the water pump
adherence or impeller • Replace the water pump, if it

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damaged. doesn''t work properly.
Immerse the thermostat • After removing the thermostat, • Replace the thermostat, if it

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in boiling water and check it works properly. doesn''t work properly.
inspection. ※ Check the thermostat opens

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at the valve opening

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temperature.

Engine Mechanical System

Replacement

• Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
• Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.

1. Park the car on level ground.

Start the engine and let it warm up.
2. Turn the engine off and open the hood.
Remove the engine cover.
3. Wait for 5 minutes after loosening the oil filter cap to drain fully the oil in the oil filter.
4. Drain engine oil.
(1) Remove the oil filler cap.
(Refer to Lubrication System - "Oil Filter")
(2) After lifting the car, remove the engine room under cover.
(3) Remove the oil drain plug (A) and drain oil into a container.
5. Replace the oil filter.
(Refer to Lubrication System - "Oil Filter")
6. Fill new engine oil.
(1) Install the oil drain plug (A) with a new gasket.
Tightening torque :
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)

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(2) Fill with new engine oil, while check the oil level on the dipstick.

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Capacity

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Total : 6.5L (6.87 US qt, 5.72lmp qt, 1.72 US.gal)
Oil pan : 6.0L (6.34 US qt, 5.28lmp qt, 1.58 US.gal)

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Drain and refill including oil filter :
5.7L (6.02 US qt, 5.01lmp qt, 1.50 US.gal)

• Fill the crankcase to about half the capacity and then fill the remainder after waiting.
• Do not fill oil over the ''F'' line, checking the level with the oil level gauge. frequently to ensure no overfilling.

(3) Install the oil filler cap and the oil dipstick.

7. Start the engine and check to be sure no oil is leaking from the drain plug or oil filter.
8. Recheck the engine oil level.

Inspection
1. Check the engine oil quality. Check the oil deterioration, addition of water or coolant, discoloring or thinning. If the quality is visibly poor,
replace the oil.
2. Check the engine oil level.
After warming up the engine and then 5 minutes after the engine stop, oil level should be between the “L” and “F” marks in the dipstick.
If low, check for leakage and add oil up to the “F” mark.

Do not fill with engine oil above the “F” mark.

Selection Of Engine Oil

Recommendation : 5W-30/A5 (If not available, refer to the recommended ACEA, API or ILSAC classification and SAE viscosity number.)
ACEA classification : A3, A5 or above
SAE viscosity grade : Refer to the recommended SAE viscosity number.

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For best performance and maximum protection of all types of operation, select only those lubricants which :

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1) Satisfy the requirement of the ACEA classification.
2) Have proper SAE grade number for expected ambient temperature range.
3) Lubricants that do not have both an SAE grade number and ACEA service classification on the container should not be used.

Engine Mechanical System

Engine oil flow diagram

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Engine Mechanical System

Components
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1. Oil filter cap 3. Oil filter element
2. O-ring 4. Oil filter body

Engine Mechanical System

Replacement
1. Remove the engine cover.
2. Wait for 5 minutes after loosening the oil filter cap to drain well the oil in the oil filter.
3. Replace the oil filter.
(1) Disconnect the oil filter cap from the oil filter body.
 (2) Remove the oil filter element.
(3) Check and clean the oil filter installation surface.
(4) Check the part number and shape of a new oil filter is same as old one.
(5) Install a new oil filter element (A) and a new O-ring (B).
Apply clean engine oil to the new O-rings.
Lightly screw the oil filter cap into place, and tighten it until the O-ring contacts the seat.

(6) Finally tighten it again by specified tightening torque.

Tightening torque :
35.0N.m (3.6kgf.m, 25.8lb-ft)

4. Start the engine and check to be sure no oil is leaking from the oil filter.
5. Recheck the engine oil level.

Engine Mechanical System

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Components

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1. Oil filter body
2. Gasket

Engine Mechanical System

Removal and Installation

1. Remove the water pipe.
(Refer to Cooling System - "Water Pipe")
2. Wait for 5 minutes after loosening the oil filter cap to drain well the oil in the oil filter.
3. Remove the oil filter body (A).
Tightening torque:
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
 Do not reuse oil filter body O-ring.

4. Installation is in the reverse order of removal.

Engine Mechanical System

Components

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1. Upper oil pan 3. Drain plug
2. Lower oil pan 4. Drain plug gasket

Engine Mechanical System

Removal
[Lower oil pan]
1. Drain the engine oil.
(Refer to Lubrication System - "Engine Oil")
2. Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")
3. 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.

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• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.

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• 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

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from the ladder frame.
• Do not use the SST as a prybar.

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Hold the tool in position (on the gasket line) and tap in with a light hammer.

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• Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.

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[Upper oil pan]
1. Remove the engine assembly from the vehicle.
(Refer to Engine And Transmission Assembly - "Engine And Transmission Assembly")
2. Attach the engine to engine stand for disassembly.
3. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
4. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
5. Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
6. Remove the LH/RH exhaust manifold stays.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
7. Remove the upper oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil pan and sylinder block. Cut off applied sealer and remove the upper oil pan.
 Installation
[Lower oil pan]
1. Install the lower oil pan (A).
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) 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.)

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• 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 protrud into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

(3) 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)

2. After assembly, wait at least 30 minutes before filling the engine with oil.
3. Install the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")

[Upper oil pan]

1. Install the upper oil pan.
a. Using a gasket scraper, remove all the old gasket meterial from the gasket surfaces.
b. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width :2.5mm (0.1in.)

• Clean the sealing face before assembling two parts.

• Remove harmful foreign materials on the sealing face before applying sealant
• When applying sealant gasket, sealant must not protrud into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

c. Install the upper oil pan.

Uniformly tighten the bolts in several passes.
Tightening torque

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9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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2. Install the other parts reverse order of removal.
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Engine Mechanical System

Components
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1. Oil pump
2. O-ring
3. Oil pump sprocket
4. Oil pump chain cover om
Engine Mechanical System

Removal
1. Remove the lower oil pan.
(Refer to Lubrication System - "Oil Pan")
2. Remove the oil pump chain cover (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
3. Remove the bolt (A) and then seperate the chain with sprocket from the oil pump.
Tightening torque :
18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

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4. Remove the oil pump (A).
Tightening torque :

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20.6 ~ 22.6N.m (2.1 ~ 2.3kgf.m, 15.2 ~ 16.6lb-ft)

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When installing, use a new O-ring.

5. Install in the reverse order of removal.

Installation
1. Install the oil pump (A).
Tightening torque :
20.6 ~ 22.6N.m (2.1 ~ 2.3kgf.m, 15.2 ~ 16.6lb-ft)
 Always use a new O-ring.

2. Install the oil pump sprocket and the oil pump chain on the oil pump, and tighten the sprocket bolt (A).
Tightening torque :
18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)

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3. Install the oil pump chain cover (A).
Tightening torque :

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9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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4. Install the lower oil pan.

(Refer to Lubrication System - "Oil Pan")
5. After assembly, wait at least 30 minutes before filling the engine with oil.

Engine Mechanical System

Components
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1. Oil cover
2. Oil cover gasket
3. Oil pressure switch
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Engine Mechanical System

Removal and Installation

1. Remove the water pipe.
(Refer to Cooling System - "Water Pipe")
2. Remove the oil pressure switch (A).
Tightening torque:
34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
 When installing, apply sealant on the thread part.

3. Installation is in the reverse order of removal.

Inspection
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

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2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is
pushed, replace the switch.

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3. If there is no continuity when a 50 kpa (7psi) is applied through the oil hole the switch is operaing properly. Check for air leakage. If air
leaks, the diaphragm is broken. Replace it.

Engine Mechanical System

Components
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1. Oil level gauge
2. Oil level gauge pipe
3. O-ring

Engine Mechanical System

Removal and Installation

1. Remove the oil level gauge (A).
Tightening torque:
18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
 When installing, apply engine oil to the O-ring and take care the O-ring not to be damaged.
Always use a new O-ring.

2. Installation is in the reverse order of removal.

Engine Mechanical System

Components

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1. Air duct 5. Breather hose

2. Air cleaner lower cover 6. Air in take hose
3. Air cleaner element 7. Resonator
4. Air cleaner upper cover 8. Clamp
9. Barometric pressure sensor

Engine Mechanical System

Removal and Installation

1. Remove the battery.
(Refer to Engine Electrical System - "Battery")
2. Remove the engine cover.
3. Remove the air duct (A).
4. Remove the air cleaner assembly.
(1) Disconnect barometric pressure sensor (BPS) connector (A)
(2) Disconnect the breather hose (B)
(3) Disconnect the intensifier hose (C)
(4) Loosen the clamp (D) and then disconnect the air intake hose from the throttle body.
Tightening torque :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

(5) Remove the air cleaner assembly (E).

Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

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5. Install in the reverse order of removal.

Engine Mechanical System

Components
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1. Surge tank
2. Surge tank stay om
Engine Mechanical System

Removal and Installation

1. Drain the coolant.
(Refer to Cooling System - "Coolant")
2. Remove the air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
3. Disconnect the engine wiring connectors and harness protector on the surge tank.
(Refer to Fuel System - "Engine Control System")
4. Disconnect the PCSV hose (A), and the throttle body water hoses (B).
5. Disconnect the PCV hose (A), and then remove the surge tank stay (B).
Tightening torque :
27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

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6. Remove the surge tank (A).
Tightening torque :

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9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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7. Installation is in the reverse order of removal.

Engine Mechanical System

Components
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1. Intake manifold

Engine Mechanical System

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Removal and Installation
1. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
2. Remove the low pressure fuel line.
(Refer to Fuel System - "Fuel Line")
3. Remove the intake manifold (A).
 • Cover the cylinder head intake port with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
• Make sure the engine and radiator are cool to the touch.
• Remove radiator cap.
• Loosen the drain plug and drain the coolant.
• Tighten the radiator drain plug securely.

Drain the engine coolant before removing the intake maniford.

Otherwise, engine coolant may enter into the intake port from the vent holes of the clylinder head and this can cause problems in the
engine combustion chambers.

4. Install in the reverse order of removal.

Tighten the intake manifold bolts and nuts, in several passes as below.

Tightening torque
Step 1: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
Step 2: 26.5 ~ 31.4N.m (2.7~3.2kgf.m, 19.5~23.1lb-ft)
Step 3: Repeat 2nd step twice or more.

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Fill the engine coolant after installing intake maniford and check coolant level.

Engine Mechanical System

Components
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1. LH Exhaust manifold gasket
2. LH Exhaust manifold
3. LH Heat protector
5. RH Exhaust manifold gasket
6. RH Exhaust manifold
7. RH Heat protector
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4. LH Exhaust manifold stay 8. RH Exhaust manifold stay

Engine Mechanical System

Removal and Installation

[LH]
1. Disconnect the LH front and rear heated oxygen sensor (HO2S) connector.
(Refer to Fuel System - "Heated Oxygen Sensor (HO2S)")
2. Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")
3. Remove the cooling fan assembly.
(Refer to Cooling System - "Cooling Fan")
4. Remove oil level gauge assembly.
(Refer to Lubrication System - "Oil Level Gauge & Pipe")
5. Remove the LH exhaust manifold heat protector (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
6. Remove the LH exhaust manifolds stay (A),and then remove the LH exhaust manifold (B) and gasket.
Tightening torque
Stay bolt :
24.5 ~ 35.3N.m (2.5 ~ 3.6kgf.m, 18.1 ~ 26.0lb-ft)
Manifold nuts :
49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)

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7. Install in the reverse order of removal.

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When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with specified torque in the

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sequence shown.

[RH]
1. Disconnect the RH front and rear heated oxygen sensor (HO2S) connector.
(Refer to Fuel System - "Heated Oxygen Sensor (HO2S)")
2. Remove the surge tank.
(Refer to Intake And Exhaust System - "Surge Tank")
3. Remove the front muffler.
(Refer to Intake And Exhaust System - "Front Muffler")
4. Remove the RH exhaust manifold heat protector (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
5. Remove the RH exhaust manifolds stay (A),and then remove the RH exhaust manifold (B) and gasket.
Tightening torque
Stay bolt :
24.5 ~ 35.3N.m (2.5 ~ 3.6kgf.m, 18.1 ~ 26.0lb-ft)
Manifold nuts :
49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)

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6. Install in the reverse order of removal.

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When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with specified torque in the

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sequence shown.

Engine Mechanical System

Components
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1. Front muffler

Engine Mechanical System

Removal and Installation

1. Disconnect the battery negative terminal.
2. Remove the engine room under cover.
3. Disconnect the heated oxygen sensor (HO2S) connector.
(Refer to Fuel System - "Heated Oxygen Sensor (HO2S)")
4. Remove the front muffler (A).
Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
5. Install in the reverse order of removal.

Engine Mechanical System

Components

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1. Catalytic converter & center muffler assembly

Engine Mechanical System

Removal and Installation

1. Disconnect the battery negative terminal.
(Refer to Engine Electrical System - "Battery")
2. Remove the catalytic converter & center muffler assembly (A).
Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
3. Install in the reverse order of removal.

Replacement procedure of center muffler using clamp

Under warranty : Replace the center muffler assembly.
Out of warranty : It is available to replace the center muffler as the procedure below.
1. Check that the clamping part of the center muffler assembly is damaged or deformed.
If the muffler is too corroded to clamp, replace the center muffler assembly.

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2. Record the gap (A, B, C, D, E, F) between the tail pipe (or tail trim) and the rear bumper.
[Pipe type]

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[Trim type]

[Bumper-integrated trim type]

3. Remove the catalytic converter & center muffler (A).

4. Cut the center muffler as the instruction below.

[With dent]

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– Cut the front dent of the muffler.

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– Cut the muffler by reffering to the front dent of A/S muffler as shown in the image below.

[A/S muffler]
– Cut the rear dent of the A/S muffler.
 • To prevent a leak, remove the rust on the clamping part or the burr on the cutting part.
• Cut the pipe vertically.

• Pipe cutter available to cut the pipe vertically.

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• Use a hacksaw as the procedure below, if a pipe cutter is unavailable.

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1) Mark the cutting position to cut the pipe vertically.

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2) Cut the pipe along the marking line by using hacksaw.

5. Install the center muffler.

(1) Install the catalytic converter (A) and the center muffler (B) for A/S by tightening the nuts lightly, not completely.
 When installing the muffler, replace the gasket with new one.

(2) Put the clamp (A) between the cutting part of each pipe and tighten the clamp lightly, not completely.

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(3) Tighten the catalytic converter and the center muffler with specified torque.

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Tightening torque :

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39.2~58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9~43.4 lb-ft)

(4) Compare the gap between the tail pipe(or tail trim) and the rear bumper with the record measured before removing the center muffler

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assembly.

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If the tail pipe is installed differently compared to the initial position, the bumper might be damaged by the pipe heat or interfere
between the tail pipe and the rear bumper.

(5) Do not tighten the clamp at a time. Tighten the clamp nuts to the specified torque, by turns.
Tightening torque :
17.6~23.5 N.m (1.8 ~ 2.4 kgf.m, 13.0~17.4lb-ft)

Do not reuse the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.

Engine Mechanical System

Components
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1. Main muffler

Engine Mechanical System

Removal and Installation

1. Disconnect the battery negative terminal.
(Refer to Engine Electrical System - "Battery")
2. Remove the main muffler (A).
Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3. Install in the reverse order of removal.