Hyundai Cars 2006-2008

Timing Chain & Sprockets 2

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Removal & Installation



3.3L & 3.8L Engines


Click image to see an enlarged view

Fig. Exploded view of cylinder head and accessory drive belt components-3.3L & 3.8L engines



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Fig. Exploded view of timing chain and related components-3.3L & 3.8L engines

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Use fender covers to avoid damaging painted surfaces.


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


    NOTE
    Mark all wiring and hoses to avoid misconnection.


    NOTE
    Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  2.  
  3. Disconnect the negative terminal from the battery.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air duct.
  8.  
  9. Remove the intake air hose and air cleaner assembly.
    1. Disconnect the AFS connector (A).
    2.  
    3. Disconnect the breather hose (B) from air cleaner hose.
    4.  
    5. Disconnect the ECM connector.
    6.  
    7. Remove the intake air hose (C) and air cleaner (D).

      Click image to see an enlarged view

      Fig. Remove the intake air hose and air cleaner assembly-3.3L & 3.8L engines

    8.  

  10.  
  11. Remove the RH front wheel.
  12.  
  13. Remove the undercover.
  14.  
  15. Remove the RH side cover.
  16.  
  17. Drain the engine coolant. Remove the radiator cap to speed draining.
  18.  
  19. Remove the upper radiator hose.
  20.  
  21. Drain the engine oil.
  22.  
  23. Remove the lower oil pan. Refer to Oil Pan, removal & installation.
  24.  
  25. Place a jack underneath the upper oil pan.
  26.  
  27. Just loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B).

    Click image to see an enlarged view

    Fig. Loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B)-3.3L & 3.8L engines

  28.  
  29. Remove the engine coolant reservoir tank (A).
  30.  
  31. Remove the engine mounting bracket (B).

    Click image to see an enlarged view

    Fig. Remove the engine coolant reservoir tank (A) and the engine mounting bracket (B)-3.3L & 3.8L engines

  32.  
  33. Loosen the A/C pipe bracket mounting bolt.
  34.  
  35. Remove the No. 1 engine mounting (A) through the lower position of the A/C pipe line.

    Click image to see an enlarged view

    Fig. Remove the No. 1 engine mounting (A) through the lower position of the A/C pipe line-3.3L & 3.8L engines

  36.  
  37. Remove the surge tank and engine wiring.
    1. Disconnect the RH oxygen sensor connector.
    2.  
    3. Disconnect the VIS solenoid valve connector (3.8L only).
    4.  
    5. Disconnect the power steering oil pressure sensor connector.
    6.  
    7. Disconnect the RH injector connector and the ignition coil connector.
    8.  
    9. Disconnect the OCV connector and knock sensor connector.
    10.  
    11. Disconnect the LH front oxygen sensor connector, alternator connector, and air compressor connector.
    12.  
    13. Disconnect the LH ignition coil connector, injector connector, condenser connector, and ground
    14.  
    15. Remove the wiring harness protector.
    16.  
    17. Disconnect the LH CMPS and oil pressure switch connector.
    18.  
    19. Disconnect the ETC connector and the knock sensor connector.
    20.  
    21. Disconnect the PCSV connector, the MAP sensor connector, and the PCSV hose.
    22.  
    23. Remove the Electronic Throttle Control (ETC) bracket.
    24.  
    25. Disconnect the water hoses from the ETC.
    26.  
    27. Disconnect the PCV hose.
    28.  
    29. Disconnect the brake vacuum hose.
    30.  
    31. Remove the surge tank stay.
    32.  
    33. Remove the connector bracket from the surge tank.
    34.  
    35. Remove the surge tank (A).
      NOTE
      Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.



      Click image to see an enlarged view

      Fig. Remove the surge tank (A)-3.3L engine



      Click image to see an enlarged view

      Fig. Remove the surge tank (A)-3.8L engine

    36.  

  38.  
  39. Remove the cylinder head cover.
    1. Remove the connector bracket (A) from the LH cylinder head cover.
    2.  
    3. Disconnect the RH ignition coil connector(A), the condenser connector (B) and remove the wiring bracket (C).

      Click image to see an enlarged view

      Fig. Remove the connector bracket (A) from the LH cylinder head cover-3.3L and 3.8L engines

    4.  
    5. Remove the LH and RH ignition coils.
    6.  
    7. Remove the LH and RH cylinder head covers.
      NOTE
      Cover the upside of engine head with a clean vinyl cover to prevent foreign materials from entering.

    8.  

  40.  
  41. Set No. 1 cylinder to TDC/compression.
    1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.
      WARNING
      Do not rotate engine counterclockwise.

    2.  
    3. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°). Do not rotate engine counterclockwise.

      Click image to see an enlarged view

      Fig. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown-3.3L and 3.8L engines

    4.  

  42.  
  43. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  44.  
  45. Remove the crankshaft damper pulley. Refer to Crankshaft Damper, removal & installation.
    NOTE
    Use the SST (flywheel stopper, 09231-3C300) to remove the crankshaft pulley bolt, after removing the starter.

  46.  
  47. Lift up the engine assembly by using the jack.
  48.  
  49. Remove the power steering pump.
  50.  
  51. Remove the air conditioner compressor.
  52.  
  53. Remove the alternator.
  54.  
  55. Remove the drive belt idler.
  56.  
  57. Remove the drive belt auto tensioner.
  58.  
  59. Remove water pump pulley.
  60.  
  61. Remove the timing chain cover (A).
    WARNING
    Be careful not to damage the contact surfaces of the cylinder block, cylinder head, or timing chain cover.


    NOTE
    Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket as the identification mark on the chain for TDC can be erased accidentally.



    Click image to see an enlarged view

    Fig. Remove the timing chain cover (A)-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Timing marks on chain and camshaft sprockets illustrated-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Timing marks on chain and crankshaft sprocket illustrated-3.3L and 3.8L engines

  62.  
  63. Install a set pin after compressing the RH timing chain tensioner.

    Click image to see an enlarged view

    Fig. Install a set pin after compressing the RH timing chain tensioner-3.3L and 3.8L engines

  64.  
  65. Remove the RH cam-to-cam guide.
  66.  
  67. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
  68.  
  69. Remove the RH timing chain.

    Click image to see an enlarged view

    Fig. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B)-3.3L and 3.8L engines

  70.  
  71. Remove the RH timing chain guide.
  72.  
  73. Remove the oil pump chain cover.
  74.  
  75. Remove the oil pump chain tensioner assembly (A).

    Click image to see an enlarged view

    Fig. Remove the oil pump chain tensioner assembly (A)-3.3L and 3.8L engines

  76.  
  77. Remove the oil pump chain guide.
  78.  
  79. Remove the oil pump chain sprocket and oil pump chain.
  80.  
  81. Remove the crankshaft sprocket that drives the oil pump.
  82.  
  83. Install a set pin after compressing the LH timing chain tensioner.
  84.  
  85. Remove the LH cam-to-cam guide (A).

    Click image to see an enlarged view

    Fig. Remove the LH cam-to-cam guide (A)-3.3L and 3.8L engines

  86.  
  87. Remove the LH timing chain auto tensioner and LH timing chain tensioner arm.
  88.  
  89. Remove the LH timing chain.
  90.  
  91. Remove the LH timing chain guide.
  92.  
  93. Remove the crankshaft sprocket.
  94.  
  95. Remove the tensioner adapter assembly (A).

    Click image to see an enlarged view

    Fig. Remove the tensioner adapter assembly (A)-3.3L and 3.8L engines

  96.  

To install:

  1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
  2.  
  3. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
  4.  
  5. Check that the tensioner piston moves smoothly when the ratchet pawl is released.
  6.  
  7. Install the jack to the upper oil pan.
  8.  
  9. The key of crankshaft must be aligned with the timing mark of timing chain cover. Then, piston of No. 1 cylinder is placed at the TDC on the compression stroke.
  10.  
  11. Install the tensioner adapter assembly.
  12.  
  13. Install the crankshaft sprocket.
  14.  
  15. Install the LH timing chain guide. Tightening torque: 14-18 ft. lbs. (20-25 Nm).
  16.  
  17. Install the LH timing chain.
    1. To install the timing chain with no slack between the camshaft and crankshaft, use the following procedure.
    2.  
    3. Place the crankshaft sprocket on first, then the timing chain guide, then the exhaust camshaft sprocket, and finally the intake camshaft sprocket.
    4.  
    5. The timing mark of each sprockets should be matched with the timing mark (color link) of the timing chain when installing the timing chain.
    6.  

  18.  
  19. Install the LH timing chain tensioner arm. Tightening torque: 14-16 ft. lbs. (19-22 Nm).
  20.  
  21. Install the chain tensioner. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  22.  
  23. Install the LH cam-to-cam guide. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  24.  
  25. Install the crankshaft sprocket.
  26.  
  27. Install the oil pump chain and the oil pump sprocket. Tightening torque: 14-16 ft. lbs. (19-22 Nm).
  28.  
  29. Install the RH timing chain guide. Tightening torque: 14-18 ft. lbs. (20-25 Nm).
  30.  
  31. Install the RH timing chain.
    1. To install the timing chain with no slack between the camshaft and the crankshaft, use the following procedure.
    2.  
    3. Place the chain on the crankshaft sprocket first, then the intake camshaft sprocket, then the exhaust camshaft sprocket.
    4.  
    5. The timing mark of each of the sprockets must be matched with the timing mark (color link) of timing chain when installing the timing chain.
    6.  

  32.  
  33. Install the RH timing chain tensioner arm. Tightening torque: 14-16 ft. lbs. (19-22 Nm).
  34.  
  35. Install the RH timing chain auto tensioner. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  36.  
  37. Install the RH cam-to-cam guide. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  38.  
  39. Install the oil pump chain guide. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  40.  
  41. Install the oil pump chain tensioner assembly. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  42.  
  43. Pull out the pins of hydraulic tensioner (LH & RH).
  44.  
  45. Install the oil pump chain cover. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  46.  
  47. After rotating the crankshaft 2 revolutions in a clockwise direction (viewed from front), confirm that the timing marks are aligned.
    WARNING
    Always turn the crankshaft clockwise.

  48.  
  49. Install the timing chain cover.
    1. The sealant locations on the chain cover and on the counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and any debris.
    2.  
    3. Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between cylinder head and cylinder block.
      NOTE
      The part must be assembled within 5 minutes after the sealant is applied. Use a bead width of 0.1 inch (2.5mm).

    4.  
    5. After applying liquid sealant TB1217H on the timing chain cover, the part must be assembled within 5 minutes.
      NOTE
      The sealant should be applied in a continuous bead. Bead width: 0.1 inch (2.5mm).

    6.  
    7. Install a new gasket to the timing chain cover.
    8.  
    9. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to aid assembly of the timing chain cover into position.
    10.  
    11. Tighten the timing cover as shown in the illustration.

      Click image to see an enlarged view

      Fig. Tighten the timing chain cover as shown-3.3L and 3.8L engines

    12.  

  50.  
  51. Wait 30 minutes after the timing chain cover was assembled before starting the engine.
  52.  
  53. Install the water pump pulley. Tightening torque: 69-87 inch lbs. (8-10 Nm).
  54.  
  55. Install the drive belt auto tensioner. Tightening torque: Bolt (B): 60-63 ft. lbs. (81-85 Nm). Bolt (C): 13-16 ft. lbs. (18-22 Nm).
  56.  
  57. Install the drive belt idler. Tightening torque: 39-43 ft. lbs. (53-58 Nm).
  58.  
  59. Install the alternator. Tightening torque: 20-25 ft. lbs. (27-33 Nm).
  60.  
  61. Install the air conditioner compressor.
  62.  
  63. Install the power steering pump.
  64.  
  65. Lower the engine assembly using the jack.
  66.  
  67. Using SST (09231-3C100), install the timing chain cover oil seal.
  68.  
  69. Using SST (09231-3C300), install the crankshaft damper pulley. Tightening torque: 210-224 ft. lbs. (284-304 Nm).
  70.  
  71. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  72.  
  73. Install the cylinder head cover.
    1. The hardening sealant located on the upper area between the timing chain cover and the cylinder head should be removed before assembling the cylinder head cover.
    2.  
    3. After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width: 0.1 inch (2.5mm).
    4.  
    5. Wait 30 minutes after the cylinder head cover was assembled before starting the engine.
    6.  
    7. Install the cylinder head cover bolts as shown in the illustration. Tightening torque: 87-104 inch lbs. (10-12 Nm).
      NOTE
      Do not reuse the cylinder head cover gasket.



      Click image to see an enlarged view

      Fig. Tighten the cylinder head cover bolts in the sequence shown-3.3L and 3.8L engines

    8.  

  74.  
  75. Install the ignition coils.
  76.  
  77. Connect the RH ignition coil connector, the condenser connector, and install the wiring bracket.
  78.  
  79. Install the connector bracket from the LH cylinder head cover.
  80.  
  81. Install the surge tank. Tightening torque: 87-104 inch lbs. (10-12 Nm).
    1. Install the connector bracket(A) on the surge tank. Tightening torque: 210-224 ft. lbs. (284-304 Nm).
    2.  
    3. Install the surge tank stay. Tightening torque: 20-23 ft. lbs. (27-31 Nm).
    4.  

  82.  
  83. Connect the brake vacuum hose.
  84.  
  85. Connect the PCV hose.
  86.  
  87. Connect the water hoses to the ETC.
  88.  
  89. Install the ETC bracket. Tightening torque: 12-19 ft. lbs. (16-26 Nm).
  90.  
  91. Connect the PCSV connector, the MAP sensor connector, and the PCSV hose.
  92.  
  93. Connect the ETC connector and the knock sensor connector.
  94.  
  95. Connect the LH CMPS and oil pressure switch connector.
  96.  
  97. Install the wiring harness protector, and connect the LH ignition connector, injector connector, condenser connector, and ground.
  98.  
  99. Connect the OCV connector and knock sensor connector.
  100.  
  101. Connect the LH front oxygen sensor connector, alternator connector, and air compressor connector.
  102.  
  103. Connect the RH injector connector and the ignition coil connector.
  104.  
  105. Connect the power steering oil pressure sensor connector.
  106.  
  107. Connect the RH oxygen sensor connector and VIS solenoid valve connector.
  108.  
  109. Connect the RH oxygen sensor connector.
  110.  
  111. Install the No. 1 engine mounting through the lower position of A/C pipe line. Tightening torque: 36-47 ft. lbs. (49-64 Nm).
  112.  
  113. Install the A/C pipe bracket mounting bolt.
  114.  
  115. Install the engine coolant reservoir tank.
  116.  
  117. Install the engine mounting bracket. Tightening torque: 47-62 ft. lbs. (64-83 Nm).
  118.  
  119. Install the transaxle mounting bolts. Tightening torque: 36-47 ft. lbs. (49-64 Nm).
  120.  
  121. Remove the jack from the upper oil pan.
  122.  
  123. Install the lower oil pan. Refer to Oil Pan, removal & installation. Uniformly tighten the bolts in several passes. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  124.  
  125. Install the upper radiator hose.
  126.  
  127. Install the side cover.
  128.  
  129. Install the undercover.
  130.  
  131. Install the front wheels.
  132.  
  133. Install the intake air hose and air cleaner assembly.
    1. Install the intake air hose and air cleaner.
    2.  
    3. Connect the ECM connector.
    4.  
    5. Connect the breather hose to air cleaner hose.
    6.  
    7. Connect the AFS connector.
    8.  
    9. Install the air duct.
    10.  

  134.  
  135. Install the engine cover.
  136.  
  137. Connect the negative terminal to the battery.
  138.  
  139. Refill the engine with the proper amount and type of engine oil.
  140.  
  141. Refill the radiator and reservoir tank with engine coolant.
  142.  
  143. Bleed the air from the cooling system.
  144.  
  145. Run the engine and check for leaks.
  146.  

 
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