Sunday, March 27, 2011

How to time the cam and crank on Hyundai accent 1.6L DOHC 2004?

Crankshaft Damper (Balancer)


Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the engine cover.
  3. Remove the front right wheel and tire.
  4. Remove the right side cover.
  5. Remove the drive belt (A), the idler (B) and the tensioner (C).
    NOTE
    In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.



    Click image to see an enlarged view

    Fig. Accessory belts location

  6. Remove the timing belt upper cover (A).

    Click image to see an enlarged view

    Fig. Timing belt upper cover location


Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover at the moment. No.1 cylinder piston at Top Dead Center (TDC).

Click image to see an enlarged view

Fig. Timing mark location

  1. Sustain the engine oil pan with a jack.
    CAUTION
    Put a wooden or rubber block between the jack and the engine oil pan.



    Click image to see an enlarged view

    Fig. Jack placement diagram

  2. Remove the engine mounting bracket (A).
  3. Remove the crankshaft damper pulley (A).

    Click image to see an enlarged view

    Fig. Crankshaft damper pulley

  4. Remove the crankshaft damper.

To install:

  1. Install the crankshaft damper.
  2. Install the crankshaft pulley. Torque mounting bolts to 133 ft. lbs. (180 Nm).
  3. Replace the engine mounting bracket.
  4. Lower the jack and remove from the vehicle.
  5. Install the upper timing belt cover.
  6. Making sure all timing and alignment marks match, install the drive belt, the idler and the tensioner.
  7. Install the right side cover.
  8. Install the right front tire and wheel.
  9. Install the engine cover.

-----------------------

Removal & Installation



2.5L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts
    Air intake assembly
    A/C compressor
    Alternator
    Power steering pump
    Front covers
    Timing belt
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Spark plug wires
    Distributor
    Fuel lines
    Intake manifold
    Exhaust manifolds
    Valve cover bolts
    Cylinder heads by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

  1. Install or connect the following:

    New head gaskets
    Cylinder heads

  2. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
  3. For 2.5L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2. Step 2: Plus 60-64 degree turn.
    3. Step 3: Plus 45-49 degree turn.

  4. Install or connect the following:

    Valve covers
    Exhaust manifolds
    Intake manifold
    Fuel lines
    Distributor
    Spark plug wires
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Timing belt and front covers
    Power steering pump
    Alternator
    A/C compressor
    Air intake assembly
    Accessory drive belts
    Negative battery cable

  5. Fill the cooling system.
  6. Start the engine and check for leaks.

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Breather hose
    Air intake hose
    Vacuum hose
    Fuel hoses
    Intake manifold
    Spark plug wires
    Ignition coil
    Upper and lower timing belt covers
    Timing belt
    Camshaft sprockets
    Heat protector and exhaust manifold
    Water pump
    Rocker arm cover
    Camshafts
    Cylinder head and discard the gasket

  5. Clean all mating surfaces of any residual gasket material.

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L XG300 Engine

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
    Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)
    Camshafts
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
    Camshaft sprockets
    Timing belt
    Upper and lower timing belt covers
    Ignition coil and spark plug wires
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
    Fuel hoses
    Vacuum hose
    Air intake hose
    Breather hose
    Upper radiator hose
    Negative battery cable

  2. Fill the cooling system to the proper level.
  3. Start the vehicle, check for leaks and repair if necessary.

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Breather hose
    Air intake hose
    Vacuum hose
    Fuel hoses
    Intake manifold
    Spark plug wires
    Ignition coil
    Upper and lower timing belt covers
    Timing belt
    Camshaft sprockets
    Heat protector and exhaust manifold
    Water pump
    Rocker arm cover
    Camshafts

  5. The cylinder head bolts should be loosened in sequence as shown.
  6. Remove the cylinder head and discard the gasket.
  7. Clean all mating surfaces of any residual gasket material. Cylinder head loosening sequence-3.5L engine

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.5L engine

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
    Cylinder head and torque the bolts in sequence to 82 ft. lbs. (115 Nm)
    Camshafts
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
    Camshaft sprockets
    Timing belt
    Upper and lower timing belt covers
    Ignition coil and spark plug wires
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
    Fuel hoses
    Vacuum hose
    Air intake hose
    Breather hose
    Upper radiator hose
    Negative battery cable

  2. Fill the cooling system to the proper level.
  3. Start the vehicle, check for leaks and repair if necessary.

4-Cylinder Engines


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Heater hose
    Air cleaner assembly
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Spark plug wires
    Distributor, if equipped
    Ignition coil
    Accessory drive belts
    Power steering pump and bracket
    Fuel lines
    Intake manifold
    Exhaust manifold
    Front cover
    Timing belt
    Valve cover bolts
    Cylinder head by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  3. For 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2. Step 2: Plus 60-65 degrees.
    3. Step 3: Plus 60-65 degrees.

  4. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  5. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2. Step 2: Plus 90 degrees.
    3. Step 3: Loosen all bolts in reverse of tightening order.
    4. Step 4: 14 ft. lbs. (20 Nm).
    5. Step 5: Plus 90 degrees.
    6. Step 6: Plus 90 degrees.

  6. Install or connect the following:

    Valve cover
    Timing belt and front cover
    Exhaust manifold
    Intake manifold
    Fuel lines
    Power steering pump and bracket
    Accessory drive belts
    Ignition coil
    Distributor, if equipped
    Spark plug wires
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Air cleaner assembly
    Heater hose
    Upper radiator hose
    Negative battery cable

  7. Fill the cooling system.
  8. Start the engine and check for leaks.



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Heater hose
    Air cleaner assembly
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Spark plug wires
    Distributor, if equipped
    Ignition coil
    Accessory drive belts
    Power steering pump and bracket
    Fuel lines
    Intake manifold
    Exhaust manifold
    Front cover
    Timing belt
    Valve cover bolts
    Cylinder head by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  3. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
  4. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2. Step 2: Plus 60-65 degrees.
    3. Step 3: Plus 60-65 degrees.

  5. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  6. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2. Step 2: Plus 90 degrees.
    3. Step 3: Loosen all bolts in reverse of tightening order.
    4. Step 4: 14 ft. lbs. (20 Nm).
    5. Step 5: Plus 90 degrees.
    6. Step 6: Plus 90 degrees.

  7. Install or connect the following:

    Valve cover
    Timing belt and front cover
    Exhaust manifold
    Intake manifold
    Fuel lines
    Power steering pump and bracket
    Accessory drive belts
    Ignition coil
    Distributor, if equipped
    Spark plug wires
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Air cleaner assembly
    Heater hose
    Upper radiator hose
    Negative battery cable

  8. Fill the cooling system.
  9. Start the engine and check for leaks.



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Heater hose
    Air cleaner assembly
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Spark plug wires
    Distributor, if equipped
    Ignition coil
    Accessory drive belts
    Power steering pump and bracket
    Fuel lines
    Intake manifold
    Exhaust manifold
    Front cover
    Timing belt
    Valve cover bolts
    Cylinder head by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  3. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
  4. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2. Step 2: Plus 60-65 degrees.
    3. Step 3: Plus 60-65 degrees.

  5. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  6. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2. Step 2: Plus 90 degrees.
    3. Step 3: Loosen all bolts in reverse of tightening order.
    4. Step 4: 14 ft. lbs. (20 Nm).
    5. Step 5: Plus 90 degrees.
    6. Step 6: Plus 90 degrees.

  7. Install or connect the following:

    Valve cover
    Timing belt and front cover
    Exhaust manifold
    Intake manifold
    Fuel lines
    Power steering pump and bracket
    Accessory drive belts
    Ignition coil
    Distributor, if equipped
    Spark plug wires
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Air cleaner assembly
    Heater hose
    Upper radiator hose
    Negative battery cable

  8. Fill the cooling system.
  9. Start the engine and check for leaks.

V6 Engine
2.5L And 2.7L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L and 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts
    Air intake assembly
    A/C compressor
    Alternator
    Power steering pump
    Front covers
    Timing belt
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Spark plug wires
    Distributor
    Fuel lines
    Intake manifold
    Exhaust manifolds
    Valve cover bolts
    Cylinder heads by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

  1. Install or connect the following:

    New head gaskets
    Cylinder heads

  2. For 2.5L and 2.7L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2. Step 2: Plus 60-64 degree turn.
    3. Step 3: Plus 45-49 degree turn.

  3. Install or connect the following:

    Valve covers
    Exhaust manifolds
    Intake manifold
    Fuel lines
    Distributor
    Spark plug wires
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Timing belt and front covers
    Power steering pump
    Alternator
    A/C compressor
    Air intake assembly
    Accessory drive belts
    Negative battery cable

  4. Fill the cooling system.
  5. Start the engine and check for leaks.

2.5L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts
    Air intake assembly
    A/C compressor
    Alternator
    Power steering pump
    Front covers
    Timing belt
    Engine control wiring harness connectors
    Intake manifold vacuum lines
    Spark plug wires
    Distributor
    Fuel lines
    Intake manifold
    Exhaust manifolds
    Valve cover bolts
    Cylinder heads by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

  1. Install or connect the following:

    New head gaskets
    Cylinder heads

  2. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
  3. For 2.5L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2. Step 2: Plus 60-64 degree turn.
    3. Step 3: Plus 45-49 degree turn.

  4. Install or connect the following:

    Valve covers
    Exhaust manifolds
    Intake manifold
    Fuel lines
    Distributor
    Spark plug wires
    Intake manifold vacuum lines
    Engine control wiring harness connectors
    Timing belt and front covers
    Power steering pump
    Alternator
    A/C compressor
    Air intake assembly
    Accessory drive belts
    Negative battery cable

  5. Fill the cooling system.
  6. Start the engine and check for leaks.

2.7L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence- 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts
    Air intake assembly
    Radiator and heater hoses
    Engine control wiring harness connectors
    Fuel lines
    Brake booster vacuum hose
    Power steering pump
    Front covers
    Timing belt
    Intake manifold vacuum lines
    Ignition coil
    Intake manifold
    Exhaust manifolds
    Valve covers
    Camshafts
    Timing belt rear cover
    Cylinder heads by loosening the bolts in sequence
    Cylinder head and discard the gasket


To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

  1. Install or connect the following:

    New head gaskets
    Cylinder heads

  2. Tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2. Step 2: Plus 60-64 degree turn.
    3. Step 3: Plus 45-49 degree turn.

  3. Install or connect the following:

    Timing belt rear cover. Tighten to 7-9 ft. lbs. (10-12 Nm).
    Camshafts
    Valve covers
    Timing belt
    Exhaust manifolds
    Power steering pump
    Intake manifold
    Brake booster vacuum hose
    Fuel lines
    Ignition coil
    Engine control wiring harness connectors
    Radiator and heater hoses
    Spark plug wires
    Air intake assembly
    Accessory drive belts
    Negative battery cable

  4. Fill the cooling system.
  5. Start the engine and check for leaks.

3.0L And 3.5L And 3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Upper radiator hose
    Breather hose
    Air intake hose
    Vacuum hose
    Fuel hoses
    Intake manifold
    Spark plug wires
    Ignition coil
    Upper and lower timing belt covers
    Timing belt
    Camshaft sprockets
    Heat protector and exhaust manifold
    Water pump
    Rocker arm cover
    Camshafts
    Cylinder head and discard the gasket

  5. Clean all mating surfaces of any residual gasket material.

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L and 3.5L engines

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
    Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)
    Camshafts
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
    Camshaft sprockets
    Timing belt
    Upper and lower timing belt covers
    Ignition coil and spark plug wires
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
    Fuel hoses
    Vacuum hose
    Air intake hose
    Breather hose
    Upper radiator hose
    Negative battery cable

  2. Fill the cooling system to the proper level.
  3. Start the vehicle, check for leaks and repair if necessary.

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