Tucson 2006-2008

Timing Belt & Sprockets

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Removal & Installation




WARNING
Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for a timing belt is 60,000 miles.

2.0L Engine

Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the timing belt front cover. Refer to Timing Belt Front Cover, removal & installation.
  4.  
  5. Remove the timing belt tensioner and timing belt.
    NOTE
    If the timing belt is to be reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before.

  6.  
  7. Remove the bolt (B) and timing belt idler (A).

    Click image to see an enlarged view

    Fig. Remove the bolt (B) and timing belt idler (A)-2.0L engine

  8.  
  9. Remove the crankshaft sprocket.
  10.  
  11. Remove the cylinder head cover.
    1. Remove the spark plug cables.
    2.  
    3. Remove the accelerator cable from the cylinder head cover.
    4.  
    5. Remove the Positive Crankcase Ventilation (PCV) hose and breather hose.
    6.  
    7. Remove the 12 bolts and cylinder head cover.
    8.  

  12.  
  13. Remove the camshaft sprocket.
    1. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B).
    2.  
    3. Remove the bolt and camshaft sprocket (C).
      WARNING
      Be careful not to damage the cylinder head and valve lifter with the wrench.



      Click image to see an enlarged view

      Fig. Remove the camshaft sprocket. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B) and remove the bolt and camshaft sprocket (C)-2.0L engine

    4.  

  14.  

To install:

  1. Install the camshaft sprocket.
    1. Temporarily install the camshaft sprocket bolt.
    2.  
    3. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the camshaft sprocket (C) bolt.
    4.  
    5. Tightening torque for the camshaft sprocket bolt: 74-89 ft. lbs. (100-120 Nm).
    6.  

  2.  
  3. Install the cylinder head cover.
    1. Install cylinder head cover (A) and 12 bolts (B).

      Click image to see an enlarged view

      Fig. Install cylinder head cover (A) and 12 bolts (B)-2.0L engine

    2.  
    3. Install the PCV hose and breather hose.
    4.  
    5. Install the accelerator cable to the cylinder head cover.
    6.  
    7. Install the spark plug cables.
    8.  

  4.  
  5. Install the crankshaft sprocket.
  6.  
  7. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at Top Dead Center (TDC) and its compression stroke.

    Click image to see an enlarged view

    Fig. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at TDC and its compression stroke-2.0L engine

  8.  
  9. Install the idler pulley and tighten the bolt to: 32-40 ft. lbs. (43-55 Nm).
  10.  
  11. Install the timing belt tensioner loosely enough for the adjuster to rotate. Make sure that the stopper of the base is leaning against the lower sealing cap on the cylinder head.
  12.  
  13. Install the timing belt so there is no slack in the order illustrated.
    NOTE
    The tensioner can be installed after the timing belt.



    Click image to see an enlarged view

    Fig. Install the timing belt in the order illustrated-2.0L engine

  14.  
  15. Check the alignment of the timing marks on each sprocket.
  16.  
  17. Remove the pin fixing the tensioner arm.
  18.  
  19. Using a hex wrench, turn the adjuster counterclockwise to make the indicator on the arm (A) align at the center of the base notch.
    WARNING
    Do not rotate the adjuster clockwise. It will result in damage to the auto tensioner.



    Click image to see an enlarged view

    Fig. Using a hex wrench, turn the adjuster counterclockwise to align the indicator on the arm (A) to the center of the base notch-2.0L engine

  20.  
  21. Tightening the tensioner bolt so the indicator does not move. Tightening torque: 17-21 ft. lbs. (23-28 Nm).
  22.  
  23. Turn the crankshaft 2 revolutions in the operating direction (clockwise) and check that the indicator is in the center of the base.
  24.  
  25. If the indicator is not located at the center of the base, slacken the bolt and repeat the above procedure.
  26.  
  27. Install the timing belt front cover. Refer to Timing Belt Front Cover, removal & installation.
  28.  

2.7L Engine

Specific to:

Hyundai Tucson 2006-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the timing belt front covers (upper and lower). Refer to Timing Belt Front Cover, removal & installation.
  4.  
  5. Remove the engine support bracket (A).

    Click image to see an enlarged view

    Fig. Remove the engine support bracket (A)-2.7L engine

  6.  
  7. Check that timing marks of the camshaft timing pulleys and cylinder head covers are aligned. If not, turn the crankshaft 1 revolution (360°).
  8.  
  9. Remove the timing belt tensioner. Alternately loosen the 2 bolts and remove the tensioner (A).

    Click image to see an enlarged view

    Fig. Alternately loosen the 2 bolts and remove the tensioner (A)-2.7L engine

  10.  
  11. Remove the timing belt.
    NOTE
    If the timing belt is to be reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before.

  12.  
  13. Remove the tensioner arm assembly (A) and timing belt idler pulley (B).

    Click image to see an enlarged view

    Fig. Remove the tensioner arm assembly (A) and timing belt idler pulley (B)-2.7L engine

  14.  
  15. Remove the crankshaft sprocket.
  16.  
  17. Remove the camshaft sprockets. Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt and camshaft sprocket.
    WARNING
    Be careful not to damage the cylinder head and valve lifter with the wrench.

  18.  

To install:

  1. Install the crankshaft sprocket: Align the pulley set key with the key groove the crankshaft sprocket and slide on the crankshaft sprocket.
  2.  
  3. Install the camshaft sprockets and tighten the bolts to the specified torque.
    1. Temporarily install the camshaft sprocket bolts.
    2.  
    3. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts. Tightening torque: 65-80 ft. lbs. (88-108 Nm).
    4.  

  4.  
  5. Install the idler pulley and the tensioner pulley. Tightening torque:
    1. Idler pulley bolt: 36-43 ft. lbs. (49-59 Nm).
    2.  
    3. Tensioner arm fixed bolt: 25-40 ft. lbs. (34-54 Nm).
      NOTE
      Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.

    4.  

  6.  
  7. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No. 1 piston placed at Top Dead Center (TDC) of its compression stroke.

    Click image to see an enlarged view

    Fig. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No. 1 piston placed at Top Dead Center (TDC) of its compression stroke-2.7L engine

  8.  
  9. Set the timing belt tensioner.
    1. Using a press, slowly press in the push rod.
    2.  
    3. Align the holes of the push rod and housing.
    4.  
    5. Pass a set pin through the holes to keep the setting position of the push rod.
    6.  
    7. Release the press.
    8.  

  10.  
  11. Install the timing belt tensioner.
    1. Temporarily install the tensioner with the 2 bolts.
    2.  
    3. Alternately tighten the 2 bolts. Tightening torque: 15-20 ft. lbs. (20-27 Nm).
    4.  

  12.  
  13. Install the timing belt.
    1. Remove any oil or water on the sprockets, and keep them clean.
    2.  
    3. Install the timing belt in this order:

      Crankshaft sprocket
       
      Idler pulley
       
      Camshaft sprocket LH side
       
      Water pump pulley
       
      Camshaft sprocket RH side
       
      Tensioner pulley
       

    4.  

  14.  
  15. Remove the set pin (A) from the tensioner.

    Click image to see an enlarged view

    Fig. Remove the set pin (A) from the tensioner-2.7L engine

  16.  
  17. Check the timing belt tensioner.
    1. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at TDC (No. 1 compression stroke) after 5 minutes.
    2.  
    3. As illustrated in the example, the projected length of the timing belt tensioner should be 0.27-0.31 inch (7-9mm).

      Click image to see an enlarged view

      Fig. The projected length of the timing belt tensioner should be 0.27-0.31 inch (7-9mm)-2.7L engine

    4.  

  18.  
  19. Install the engine support bracket (A). Tightening torque of the following bolts (see illustration):
    1. B: 43-51 ft. lbs. (59-67 Nm).
    2.  
    3. C: 11-16 ft. lbs. (15-22 Nm).

      Click image to see an enlarged view

      Fig. Install the engine support bracket (A)-2.7L engine

    4.  

  20.  
  21. Install the timing belt front covers (upper and lower). Refer to Timing Belt Front Cover, removal & installation.

    Click image to see an enlarged view

    Fig. Timing belt system and related components-2.7L engine

  22.  

 
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