Complete replacement of the timing chain, guides, tensioners, and related components on the 2.5L I4 engine, ensuring proper timing alignment and preventing catastrophic engine failure.

Warnings

Tools required

Parts

• Timing chain kit (includes chain, guides, tensioners, gaskets) × 1 — Use OEM Hyundai/Kia kit
• Timing cover gasket × 1 — Usually included in kit
• Valve cover gasket and grommets × 1 — Use OEM specification
• Crankshaft front oil seal × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil and filter × 1 — 0W-20 specification
• Engine coolant × 1 — Hyundai/Kia Long Life Green

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks
2. Disconnect negative battery cable and wait 15 minutes for airbag system discharge
3. Remove engine cover and any upper decorative covers
4. Drain engine coolant into suitable container by opening radiator drain and lower coolant hose
5. Drain engine oil and remove oil filter, install new crush washer on drain plug
6. Remove air intake assembly and air filter box for access
7. Support engine from above using engine support fixture or secure hoist connection to engine lifting point
8. Raise and support vehicle on jack stands, remove right front wheel and inner fender splash shield
9. Remove drive belt(s) and accessory drive components as needed for timing cover access
10. Remove upper and lower radiator hoses, mark for reinstallation position

Procedure

1. 1

   Remove valve cover
   Disconnect ignition coils and any wiring harnesses attached to valve cover. Remove PCV hoses and breather hoses. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover off and set aside. Clean all gasket surfaces thoroughly.
2. 2

   Remove crankshaft pulley
   Remove right engine mount to access crankshaft pulley. Use crankshaft holding tool or have assistant apply brake while loosening. The crankshaft pulley bolt requires significant force to remove - use breaker bar or impact wrench. Remove bolt and pulley, noting any alignment keys or woodruff keys.
   ⚠Crankshaft pulley bolt is often torque-to-yield and may require replacement. Check service manual specification.
   Torque spec

   Crankshaft pulley bolt215 Nm (159 lb-ft)
3. 3

   Remove timing chain cover
   Remove all timing cover bolts noting their different lengths and locations (6mm, 8mm, and 10mm bolts). Carefully separate timing cover from engine block using plastic pry tool if needed. Remove old gasket material and clean all sealing surfaces with gasket scraper and solvent. Inspect cover for cracks or damage. Remove and replace crankshaft front seal from timing cover.
   Torque spec

   Timing cover bolts22 Nm (16 lb-ft)
4. 4

   Verify and document timing marks
   Rotate crankshaft clockwise to TDC cylinder #1 (compression stroke). Verify all timing marks align: crankshaft keyway at 12 o'clock, camshaft sprocket marks aligned with cylinder head surface or timing marks, cam phasers in correct position. Take multiple photos from different angles showing chain routing around all sprockets and guides. This documentation is critical for correct reassembly.
   ⚠️Do not proceed until all timing marks are verified and documented. Incorrect reassembly will destroy the engine.
5. 5

   Remove timing chain tensioners
   Remove timing chain tensioner mounting bolts. The tensioners may be spring-loaded - control removal carefully. Note the orientation and position of each tensioner for reinstallation. Remove tensioner bolts and extract tensioners from engine block.
   Torque spec

   Tensioner bolts11 Nm (8 lb-ft)
6. 6

   Remove timing chain guides
   Remove all timing chain guide mounting bolts. Note that some guides may have different bolt sizes. Carefully remove guides, inspecting for wear grooves or damage. The guides control chain routing and must be replaced if worn beyond specification.
   Torque spec

   Chain guide bolts11 Nm (8 lb-ft)
7. 7

   Remove camshaft sprockets and phasers
   Hold each camshaft stationary using wrench on hex section of camshaft. Remove camshaft sprocket bolts and cam phaser bolts (intake cam has phaser, exhaust has fixed sprocket). Note the position and orientation of each component. Mark intake vs exhaust components to prevent mixing during reinstallation.
   ⚠Camshafts must be held stationary to prevent rotation during bolt removal. Do not allow cams to spin freely.
8. 8

   Remove timing chain and crankshaft sprocket
   Remove idler sprocket bolt if equipped. Lift timing chain off crankshaft sprocket and remove chain from engine. Remove crankshaft sprocket by pulling straight off crankshaft - may require gentle prying. Inspect crankshaft keyway for damage. Clean all components and inspect sprocket teeth for wear.
9. 9

   Inspect and prepare new components
   Inspect all new timing chain kit components. Verify chain length matches old chain when laid side by side. Check that all guides, tensioners, and gaskets are included. Pre-compress new tensioners using tensioner compression tool or carefully in vise, install retaining pin or clip to keep compressed. Apply clean engine oil to chain and sprocket surfaces.
   ℹ️New timing chain should match old chain link count exactly. Verify before installation.
10. 10

    Install crankshaft sprocket and timing chain
    Install crankshaft sprocket onto crankshaft with timing mark visible, ensuring keyway or alignment features properly engage. Route new timing chain around crankshaft sprocket, verifying mark alignment. Route chain around idler sprocket if equipped and install idler bolt finger-tight. Position chain for camshaft sprocket installation per factory routing diagram.
11. 11

    Install camshaft sprockets and phasers
    Rotate camshafts to align with timing marks if needed. Install cam phaser on intake cam and fixed sprocket on exhaust cam, routing timing chain over sprockets with timing marks aligned. Apply threadlocker to cam phaser bolts as specified. Hold each camshaft with wrench on hex and torque sprocket bolts and phaser bolts to specification in correct sequence.
    ⚠️Verify all timing marks are perfectly aligned before torquing bolts. Rotate engine by hand two full revolutions and recheck all marks.
12. 12

    Install timing chain guides and tensioners
    Install all timing chain guides in their original positions, ensuring correct routing around chain. Torque guide bolts to specification. Install compressed timing chain tensioners with retaining pins still installed. Torque tensioner bolts to specification. After all tensioners are secured, carefully remove retaining pins to apply tension to chain. Verify chain has proper tension and no slack.
    Torque spec

    Chain guide bolts11 Nm (8 lb-ft)

    Tensioner bolts11 Nm (8 lb-ft)
13. 13

    Verify timing and rotate engine
    With all components installed and tensioners released, verify all timing marks are still aligned. Manually rotate crankshaft clockwise two complete revolutions using socket on crankshaft bolt. Check that all timing marks realign at TDC position. If marks do not align, disassemble and correct timing chain installation. Repeat until marks align consistently through multiple rotations.
    ⚠️Engine must rotate freely with no binding. Timing marks must realign perfectly after two revolutions. Any deviation indicates incorrect installation.
14. 14

    Install timing cover with new gasket
    Apply thin bead of RTV silicone to timing cover mating surface per factory specification (typically at oil pan junction and cylinder head junction). Install new timing cover gasket. Position timing cover carefully, ensuring crankshaft seal lip does not damage. Install all timing cover bolts finger-tight, noting correct bolt lengths for each position. Torque bolts in sequence from center outward: 6mm bolts, then 8mm bolts, then 10mm bolts to their respective specifications.
    ⚠Allow RTV to cure per manufacturer specification before filling with oil. Typically 1 hour before oil fill, 24 hours before startup.
    Torque spec

    Timing cover bolts22 Nm (16 lb-ft)
15. 15

    Reinstall crankshaft pulley and remaining components
    Install crankshaft pulley onto crankshaft, aligning any keyways or locating features. Install crankshaft pulley bolt and torque to specification. If bolt is TTY, replace with new bolt per service manual. Reinstall right engine mount. Install valve cover with new gasket and grommets, torquing bolts in sequence from center outward. Reinstall all accessory components, drive belts, hoses, and wiring removed during disassembly.
    Torque spec

    Crankshaft pulley bolt215 Nm (159 lb-ft)

Reassembly

1. Reinstall inner fender splash shield and right front wheel, torque lug nuts to specification
2. Refill engine with specified 0W-20 engine oil (5.0 quarts) and install new oil filter
3. Refill cooling system with Hyundai/Kia Long Life Coolant (approximately 10 quarts total capacity)
4. Reconnect negative battery cable
5. Prime fuel system if necessary by cycling ignition without starting
6. Reinstall engine covers and air intake assembly

Verification

• Before starting engine, remove spark plugs and rotate engine by hand multiple complete revolutions to verify no interference and proper timing
• Reinstall spark plugs and start engine, listening for abnormal noises - chain rattle, knocking, or valve contact indicates timing error
• Engine should start normally and idle smoothly without misfires or rough running
• Check for oil leaks around timing cover and valve cover, particularly at RTV seal areas
• Check for coolant leaks at all hose connections
• Allow engine to reach operating temperature and verify cooling system operation
• Perform test drive and verify normal engine performance under load
• Recheck oil level after test drive and top off if necessary
• Monitor for any check engine lights or timing-related codes in first 100 miles of operation

More procedures for this vehicle