Repair Procedures: Installation

(Refer to LUBRICATION SYSTEM - SONATA HEV article)

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

Fig 1: Installing Crankshaft Chain Sprocket And Timing Chain Oil Jet

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

Fig 4: Identifying Timing Chain Guide

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Crankshaft sprocket (A) Timing chain guide (B) Intake CVVT sprocket (C) Exhaust CVVT sprocket (D).

Fig 5: Identifying Crankshaft Sprocket, Timing Chain Guide, Intake CVVT Sprocket And Exhaust CVVT Sprocket

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Fig 6: Identifying Timing Marks Of Sprockets

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Fig 7: Identifying Timing Mark & Timing Chain Link At Crankshaft

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

Fig 8: Installing Timing Chain Tensioner Arm

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

Fig 9: Identifying Timing Chain Auto Tensioner And Stopper Pin

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1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and etc.
3. Before assembling the timing chain cover, liquid sealant Loctite 5900H or equivalent 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:  2.5 mm (0.10 in.)

   Fig 11: Identifying Gap Between Cylinder Head And Cylinder Block

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4. After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.

   The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.

   Bead width:  3.0 mm (0.12 in.)

   Fig 12: Identifying Sealant Application Area

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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: 

   Bolts A (M6x25):

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

   Bolts B (M8x28):

   18.6 ~ 22.5 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

   Fig 13: Identifying Dowel Pins On Cylinder Block And Holes On Timing Chain Cover

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   CAUTION: The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.

Tightening torque: 

M10 bolts: 39.2 ~ 44.1 N.m (4.0 ~ 4.5 kgf.m, 28.9 ~ 32.5 lb-ft)

M8 bolts: 19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)

Fig 14: Identifying Engine Support Bracket

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

Fig 16: Installing Water Pump Pulley And Dust Cover

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Tightening torque: 

Crankshaft pulley (A):

166.6 ~ 176.4 N.m (17.0 ~ 18.0 kgf.m, 122.9 ~ 130.1 lb-ft)

Idler (B)

53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)

Fig 17: Identifying Crankshaft Pulley And Idler

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1. Remove the service cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
   Fig 18: Identifying Service Cover And Transaxle Mounting Bolts

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2. Rotate the crankshaft pulley clockwise until a groove (A) on the torsion damper comes in sight.
   Fig 19: Identifying Groove On Torsion Damper

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3. Adjust the length of the holder (A) so that the front plate of the holder (B) puts in the groove at the closest position.
4. Adjust the angle of the links (C) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
   Fig 20: Identifying Holder, Front Plate Of Holder And Angle Of Links

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5. Install the SST (09231-3D100, 09231-3D200) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.

Fig 21: Installing SST (09231-3D100, 09231-3D200) Using Transaxle Mounting Bolts And Spacers

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Tightening torque:  88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 22: Ground Line & Engine Mounting Support Bracket

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1. Using a gasket scraper, remove all the old sealant material from the gasket surfaces.
2. Before assembling the oil pan, liquid sealant Loctite 5900H, Threebond 1217H or equivalent should be applied on oil pan. The part must be assembled within 5 minutes after sealant was applied.

   Bead width:  2.5 mm (0.10 in.)

   Fig 23: Sealant Applying Area On Oil Pan

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   CAUTION:

   • When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
   • To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
3. Install the oil pan (A). Uniformly tighten the bolts in several passes.

   Tightening torque 

   Bolts B (M9):

   26.5 ~ 30.4 N.m (2.7 ~ 3.1 kgf.m, 19.5 ~ 22.4 lb-ft)

   Bolts C (M6):

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

   Fig 24: Installing Oil Pan

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   CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
   NOTE: Always use a new drain plug gasket.

Tightening torque:  19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)

Fig 25: Installing A/C Compressor Bracket

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Tightening torque: 

Bolt A:

21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)

Bolts B:

20.0 ~ 33.0 N.m (2.04 ~ 3.36 kgf.m, 14.8 ~ 24.3 lb-ft)

Fig 26: Removing/Installing One Side Bolt And Two Lower Bolts On A/C Compressor

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1. Rotate the drive belt tensioner arm (C) clockwise moving the tensioner pulley bolt with wrench. After putting the belt on the tensioner pulley, release the tensioner pulley slowly.

   HSG pulley Tensioner #1 pulley Crankshaft pulley Idler Tensioner #2 pulley

2. Remove a stopper pin (B) on the drive belt #1 tensioner (A).

Fig 27: Rotating Arm Clockwise And Counterclockwise & Inserting/Removing Stopper Pin

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Fig 28: Identifying Water Pump Drive Belt

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1. Put the SST (09252-03200) between the crankshaft pulley and the drive belt.
2. Rotate the crankshaft pulley clockwise. Then the drive belt is installed.

Fig 29: Rotating Crankshaft Pulley Clockwise

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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 sealant, it should be assembled within 5 minutes.

   Bead width:  2.5 mm (0.10 in.)

   Fig 30: Identifying Area Between Timing Chain Cover And Cylinder Head

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3. Install the cylinder head cover (A) by tightening the bolts as following method.

   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)

   Fig 31: Cylinder Head Cover

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   Fig 32: Cylinder Head Cover Bolts Tightening Sequence

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   CAUTION:

   • Do not reuse cylinder head cover gasket.
   • The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.

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

Fig 33: Ignition Coils

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(Refer to ENGINE AND TRANSAXLE ASSEMBLY )

(Refer to "WHEEL ")

(Refer to ENGINE AND TRANSAXLE ASSEMBLY )

Tightening torque:  4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)