| VELOSTER(FS) >2012 > G 1.6 GDI > Engine Mechanical System > Timing System > Timing Chain>Repair procedures |

Removal
Engine removal is not required for this procedure.
• | 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.
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
1. | Remove the engine cover.
2. | Disconnect the battery negative terminal (A).
3. | Remove the air cleaner assembly.
(1) | Remove the air duct (A).
(2) | Disconnect the breather hose (B).
(3) | Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
4. | Remove the RH front wheel.
5. | Remove the under covers (A).
6. | Disconnect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator “B” terminal (C).
7. | Disconnect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).
8. | Disconnect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).
9. | Disconnect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).
10. | Disconnect the oxygen sensor connectors (A) and the condenser connector (B).
11. | Disconnect the fuel hose (A) and the PCV (Positive crankcase ventilation) hose (B).
12. | Remove the vacuum pipe assembly (A).
13. | Remove the high pressure pipe (A). (Refer to FL group)
14. | Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to FL group)
15. | Remove the ignition coils (A).
16. | Remove the exhaust OCV (Oil control valve) (B).
17. | Remove the cylinder head cover (A) with gaskets (B).
18. | Remove the exhaust OCV (Oil control valve) adapter (A).
19. | Loosen the water pump pulley bolt and the drive idler mounting bolt.
20. | Loosen the alternator tension adjusting bolt (A) to loosen tension.
21. | Remove the alternator drive belt (A).
22. | Remove the alternator (A). (Refer to Altemator in EE Group).
23. | Disconnect the ground line (A) and then remove the engine mounting support bracket (A).
Support the engine with a jack not to be tilted.
24. | Remove the alternator bracket (B).
25. | Remove the engine support bracket (A).
26. | Remove the water pump pulley (A) and the drive belt idler (B).
27. | Remove the water pump (A).
28. | Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.
29. | Remove the crankshaft bolt (B) and crankshaft pulley (A).
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.
• | Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. | Remove the bracket (A).
2. | Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
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. | Adjust the angle of the links (D), and fasten the bolt 70mm(2.7559in) in the original mounted hole.
5. | Tighten the bolts and nuts of the holder and links securely.
30. | Remove the timing chain cover (A).
31. | Align the timing marks of the CVVT sprockets with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC.
(1) | Check the dowel pin of the crankshaft for facing upside of the engine at this monent.
Put paint marks on the timing chain links(3 places) that meet with the timing marks of the CVVT sprockets(In, Ex : 2) and the CVVT sprocket.
32. | Remove the hydraulic tensioner (A).
Before removing the tensioner, fix the piston of the tensioner with a pin through the hole(B) at compressed position.
33. | Remove the timing chain tensioner arm (A) and guide (B).
34. | Remove the timing chain (A).
Inspection
Sprockets, Hydraulic Tensioner, Chain Guide, Tensioner Arm, Timing Chain
1. | Check the CVVT sprocket, crankshaft sprocket teeth for abnormal wear, cracks or damage. Replace if necessary.
2. | Check a contact surface of the chain tensioner arm and guide for abnormal wear, cracks or damage. Replace if necessary.
3. | Check the hydraulic tensioner for its piston stroke and ratchet operation. Replace if necessary.
4. | Check the timing chain for its elongation, abnormal wear or damage. Replace if necessary.
Belt, Idler, Pulley
1. | Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necssery.
2. | Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necssery.
3. | Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necssery.
• | Do not bend, twist or turn the timing chain inside out.
• | Do not allow the timing chain to come into contact with oil, water and steam.
Installation
1. | Dowel pin of crankshaft should be positioned at 3° in relation to vertical center line.
2. | Align the TDC marks (A) of the CVVT sprockets with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC.
3. | Install the new O-rings (A).
4. | Install the timing chain guide (A) and the timing chain (B).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain. Order : Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket.
5. | Install the chain tensioner arm (A).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. | Install the hydraulic tensioner (A) and remove the pin (B).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Recheck the top dead center (TDC) marks on the crankshaft and camshaft.
7. | Install the timing chain cover.
(1) | Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
(2) | Apply the liquid gasket(TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.
Width : 3 ~ 5mm (0.1181~0.1969in.)
(3) | Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts (A) of the timing chain cover and Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the rest parts (B). Reassemble the cover within 5 minutes.
Width : 3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
Remove oil or dust on the surface surely.
(4) | Align the dowel pin of the cylinder block and the holes of the oil pump.
(5) | Tighten the bolts to install the timing chain cover (A).
Tightening torque : M8 bolts : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft) M6 bolts : 9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
After the installation, do not crank engine or apply pressure on the cover for half an hour.
8. | Using the SST(09455-21200), reassemble the timing chain cover oil seal.
9. | Install the crankshaft pulley (A).
Tightening torque : 127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lb-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.
• | Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. | Remove the bracket (A).
2. | Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
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. | Adjust the angle of the links (D), and fasten the bolt 70mm(2.7559in) in the original mounted hole.
5. | Tighten the bolts and nuts of the holder and links securely.
When installing the pulley, the groove on the pulley should be positioned outside.
10. | Install the water pump (A) with a gasket.
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. | Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque : A: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) B: 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
Tighten the bolts diagonally.
12. | Install the engine support bracket (A).
Tightening torque : 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
13. | Install the alternator bracket (B).
Tightening torque : 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
14. | Install the engine mounting support bracket (B) and then connect the ground line (A).
Tightening torque Ground line bolt : 10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft) Nut (C) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft) Bolt (D) and nuts (E) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
15. | Install the alternator (A).
Tightening torque : M8 bolt : 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft) M10 bolt : 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
16. | Install the drive belt (A).
17. | Adjust tension by tightening the alternator tension adjust bolt (A).(Refer to Charging system in EE Group).
Tension New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb) Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
18. | Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
19. | After applying the liquid gasket, Hyundai Gray RTV or THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.
Width : 2.0 ~ 2.5mm(0.0787~0.0984in.)
20. | Install the OCV (Oil Control Valve) adapter (A).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
• | Keep the OCV adapter clean.
• | Make sure the O-rings on the front bearing cap are installed.
21. | Install the cylinder head cover (A) with a new gasket (B).
Do not reuse the disassembled gasket.
22. | Tighten the cylinder head cover bolts with the order and steps.
Tightening torque : 1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft) 2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
23. | Install the exhaust OCV (Oil Control Valve) (A).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
24. | Install the ignition coils (A).
Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
25. | Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to FL group)
Tightening torque : 12.7 ~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8lb-ft)
Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
Do not use already used bolt again.
When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.
Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.
26. | Install the high pressure pipe (A). (Refer to FL group)
Tightening torque : 25.5 ~ 31.4N.m (2.6 ~ 3.2kgf.m, 18.8 ~ 23.1lb-ft)
Do not reuse the high pressure pipe.
27. | Install the vacuum pipe assembly (A).
Tightening torque : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
28. | Connect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
29. | Connect the oxygen sensor connectors (A) and the condenser connector (B).
30. | Connect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).
31. | Connect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).
32. | Connect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).
33. | Connect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator “B” terminal (C).
Tightening torque : 9.8 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.8lb-ft)
34. | Install the under covers (A).
Tightening torque : 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
35. | Install the RH front wheel.
36. | Install the air cleaner assembly.
(1) | Install the air cleaner assembly (D) and then connect the air intake hose (C).
Tightening torque : Hose clamp bolt : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft) Air cleaner assembly bolts : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(2) | Connect the breather hose (B).
(3) | Install the air duct (A) .
• | Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
• | Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
37. | Connect the battery negative terminal (A).
Tightening torque : Without battery sensor : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) With battery sensor : 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
38. | Install the engine cover.
Make sure the engine cover is installed before driving.