Complete removal and replacement of intake and exhaust camshafts on the 2.5L I4 engine, including timing chain removal, camshaft bearing cap removal, and timing system reassembly.

Warnings

Tools required

Parts

• Intake camshaft × 1 — Use OEM specification
• Exhaust camshaft × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain (if replacement needed) × 1 — Use OEM specification
• Timing chain tensioner × 1 — Use OEM specification
• Timing chain guides (if worn) × 2 — Use OEM specification
• Camshaft seals × 2 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• VVT solenoid O-rings (if disturbed) × 2 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
2. Remove engine cover and any decorative trim
3. Drain engine oil completely and remove oil filter
4. Drain coolant to below radiator hose level
5. Remove air intake system and air filter housing
6. Disconnect all electrical connectors from valve cover, including VVT solenoids and camshaft position sensors
7. Remove upper radiator hose and any coolant lines connected to cylinder head
8. Support engine with engine support fixture or hoist from above
9. Remove right side engine mount to allow access to timing cover
10. Position vehicle on level surface and set crankshaft to TDC cylinder #1 compression stroke
11. Photograph or mark all timing chain alignment marks before disassembly

Procedure

1. 1

   Remove valve cover
   Remove ignition coils and spark plugs. Unbolt valve cover in reverse torque sequence (outside to inside). Carefully lift valve cover away from cylinder head. Clean all gasket material from mating surfaces using plastic scraper.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
2. 2

   Remove crankshaft pulley and harmonic balancer
   Lock crankshaft using holding tool. Remove crankshaft pulley bolt (may require impact gun). Use harmonic balancer puller to remove balancer from crankshaft without damaging front seal or timing cover.
   ⚠Do not use jaw-type puller that grips outer edge of balancer, as this will damage it. Use only proper harmonic balancer puller.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing cover
   Remove all timing cover bolts, noting different lengths and locations (8mm and 10mm bolts). Carefully pry timing cover away from engine block using plastic pry tools at designated pry points only. Remove cover and gasket.
   ⚠Do not pry between cover and block at random locations as this can damage sealing surfaces.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
4. 4

   Verify and mark timing alignment
   Confirm crankshaft is at TDC for cylinder #1. Verify all timing marks on camshaft sprockets align with marks on cylinder head. Verify timing chain colored links align with marks on crankshaft and camshaft sprockets. Take detailed photos. Mark camshaft sprockets and chain relationship with paint marker.
   ⚠️If timing marks do not align with engine at TDC, do not proceed. Engine may have jumped timing and require further inspection.
5. 5

   Remove timing chain tensioner and guides
   Remove timing chain tensioner mounting bolt and carefully extract tensioner. Remove timing chain guide bolts and remove upper and lower chain guides. Inspect guides for wear grooves; replace if depth exceeds 1mm.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
6. 6

   Remove camshaft sprockets and timing chain
   Hold each camshaft stationary using wrench on hexagonal section of camshaft (between lobes). Remove intake and exhaust camshaft sprocket bolts. Carefully remove sprockets and timing chain as an assembly. If equipped with cam phasers, note orientation before removal.
   ⚠Do not allow camshafts to rotate after sprockets are removed, as valves may contact pistons.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Cam Phaser Bolt65 Nm (48 lb-ft)
7. 7

   Remove camshaft bearing caps
   Using paint marker or permanent marker, clearly mark each camshaft bearing cap with its position number and orientation arrow pointing toward front of engine. Loosen bearing cap bolts in reverse sequence (outside to inside) in multiple passes, loosening each bolt 1-2 turns per pass. Remove bolts and caps, keeping them in exact order.
   ⚠️Loosening bearing caps unevenly or out of sequence will bend camshafts. Loosen gradually in at least 3 passes.
   ⚠️Each bearing cap is machined with its specific bore. Installing caps in wrong positions will cause immediate camshaft seizure and failure.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
8. 8

   Remove camshafts
   Carefully lift intake and exhaust camshafts straight up and out of cylinder head. Immediately identify and mark each camshaft (intake vs exhaust). Inspect camshaft lobes and journals for scoring, pitting, or wear. Measure lobe height and journal diameter; replace if out of specification.
   ⚠Handle camshafts carefully to avoid damage to lobes or journals. Do not allow camshafts to rest on lobes.
9. 9

   Inspect and clean cylinder head
   Inspect camshaft bearing surfaces in cylinder head for scoring or damage. Clean all bearing surfaces thoroughly with clean lint-free cloth and solvent. Verify valve lash adjusters (if equipped) move freely; replace if stuck. Clean all timing chain debris and old gasket material from engine.
10. 10

    Install new camshafts
    Liberally coat all camshaft lobes and journals with clean engine oil. Install intake and exhaust camshafts in correct positions, ensuring they are oriented correctly (typically with cam lobes in specific orientation for TDC #1). Verify camshafts rotate smoothly by hand.
    ⚠Failure to pre-lubricate camshafts will cause immediate scoring and damage during first startup.
11. 11

    Install camshaft bearing caps
    Apply light coat of clean engine oil to bearing cap surfaces. Install bearing caps in their exact original positions with orientation arrows pointing toward front of engine. Hand-start all bolts. Tighten bolts in sequence from center outward in 3 passes: first pass to 5 Nm, second pass to 10 Nm, final pass to specification. Verify camshafts rotate smoothly after each pass.
    ⚠️Tighten in multiple passes only. Tightening caps to full torque in single pass will distort camshaft journals and cause immediate failure.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
12. 12

    Prepare and install timing chain tensioner
    Compress new or cleaned timing chain tensioner and lock in compressed position using tensioner pin or appropriate clip. Install new timing chain guides (if replacing) and torque mounting bolts. Prepare to install timing chain.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)
13. 13

    Install timing chain and camshaft sprockets
    Rotate camshafts to TDC position for cylinder #1 (verify cam lobes are positioned correctly). Install timing chain onto crankshaft sprocket first, ensuring colored link aligns with crankshaft timing mark. Route chain around idler sprocket. Install chain onto exhaust camshaft sprocket, then intake sprocket, aligning colored links with sprocket marks. Install sprockets onto camshafts.
    ⚠️Triple-check all timing mark alignments before tightening sprocket bolts. Incorrect timing will destroy engine.
    Torque spec

    Timing Chain Idler Sprocket25 Nm (18 lb-ft)
14. 14

    Secure camshaft sprockets
    Hold each camshaft stationary using wrench on hex section. Apply medium-strength threadlocker to cam phaser bolts (if equipped). Tighten camshaft sprocket bolts or cam phaser bolts to specification. Verify all timing marks still align correctly after tightening.
    ⚠Camshaft must be held completely stationary during sprocket bolt tightening to prevent rotation.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Cam Phaser Bolt65 Nm (48 lb-ft)
15. 15

    Install timing chain tensioner and verify timing
    Install timing chain tensioner with pin/clip still engaged. Torque tensioner mounting bolt to specification. Carefully remove tensioner pin/clip to allow tensioner to apply pressure. Rotate crankshaft 2 complete revolutions clockwise (viewed from front). Verify all timing marks align perfectly at TDC #1. If marks do not align, disassemble and repeat timing chain installation.
    ⚠️Do not rotate engine counterclockwise as this can cause timing chain to slip and valves to contact pistons.
    Torque spec

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
16. 16

    Install timing cover
    Clean timing cover mating surfaces thoroughly. Install new timing cover gasket (do not use RTV unless specified). Position timing cover carefully, ensuring it seats properly on alignment dowels. Install all timing cover bolts finger-tight, then torque in sequence: 8mm bolts first, then 10mm bolts.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
17. 17

    Install harmonic balancer and crankshaft pulley
    Ensure crankshaft nose and balancer bore are clean and dry. Install harmonic balancer, ensuring it seats fully on crankshaft. Install new crankshaft pulley bolt (if TTY type). Torque balancer bolt to specification using holding tool to prevent rotation.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
18. 18

    Install valve cover and sensors
    Install new valve cover gasket in groove. Clean valve cover bolt threads. Install valve cover and torque bolts in sequence from center outward. Install VVT solenoids with new O-rings and torque. Install camshaft position sensors and torque.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    VVT Solenoid Bolt10 Nm (7 lb-ft)

    Camshaft Position Sensor10 Nm (7 lb-ft)

Reassembly

1. Reinstall right side engine mount and torque mounting bolts to specification
2. Remove engine support fixture
3. Reconnect all coolant hoses and electrical connectors
4. Reinstall air intake system and air filter housing
5. Install new oil filter and fill engine with 5.0 quarts of Hyundai Genuine 0W-20 oil
6. Refill coolant system and bleed air from system
7. Reinstall engine covers and decorative trim
8. Reconnect negative battery terminal

Verification

• With spark plugs removed, rotate engine by hand 4 complete revolutions and verify smooth rotation with no binding or unusual resistance
• Verify all timing marks align correctly at TDC after rotation test
• Install spark plugs and ignition coils
• Start engine and listen for any abnormal noises during first 30 seconds (normal to hear ticking until oil pressure builds)
• Check for oil leaks at valve cover and timing cover
• Verify no check engine lights or timing-related fault codes
• Allow engine to reach operating temperature and verify smooth idle
• Road test vehicle and verify normal engine performance with no misfires or hesitation
• Recheck oil level after test drive and top off if necessary

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