This procedure replaces the timing chain tensioner on the 2.5L I4 engine, requiring removal of the timing cover and precise alignment of timing marks to prevent engine damage.

Warnings

Tools required

Parts

• Timing chain tensioner assembly × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• Engine oil and filter × 1 — Use OEM specification
• RTV silicone gasket maker × 1 — Hyundai OEM equivalent

Fluids

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

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after running)
2. Disconnect negative battery cable and isolate from battery terminal
3. Raise and support vehicle securely on jack stands
4. Remove engine splash shield and undertray panels
5. Drain engine oil completely into suitable container
6. Drain coolant from radiator and engine block into suitable container
7. Remove engine cover (pull upward to release from grommets)
8. Remove air intake assembly and air filter housing
9. Label and photograph all electrical connectors before disconnecting

Procedure

1. 1

   Remove accessory drive belt and components
   Rotate the drive belt tensioner clockwise using a 14mm wrench to release tension. Remove the accessory drive belt. Remove the drive belt tensioner assembly (3 bolts). Remove the alternator mounting bolts and position alternator aside without disconnecting wiring. Remove air conditioning compressor mounting bolts and secure compressor aside without disconnecting refrigerant lines.
2. 2

   Remove valve cover
   Disconnect ignition coil connectors and PCV hoses. Remove the four ignition coils (one bolt each). Remove valve cover bolts in reverse of tightening sequence (starting from outside, working inward). Carefully lift valve cover away from cylinder head. Clean all gasket material from mating surfaces using plastic scraper.
3. 3

   Position engine at TDC cylinder #1
   Rotate crankshaft clockwise using a socket on the crankshaft pulley bolt until the timing mark on the crankshaft pulley aligns with the TDC mark on the timing cover. Verify that the intake and exhaust camshaft sprocket timing marks align with the cylinder head surface. Take multiple reference photos showing all timing mark positions. Mark the chain-to-sprocket relationship with paint pen on both camshaft sprockets.
   ⚠Only rotate engine in clockwise direction (from front of engine). Counter-clockwise rotation may damage timing components.
4. 4

   Remove crankshaft pulley
   Install crankshaft holding tool or have assistant hold flywheel from rotating using a large screwdriver through inspection cover. Remove crankshaft pulley bolt (clockwise to loosen). Use harmonic balancer puller to remove crankshaft pulley from crankshaft snout. Do not use excessive force or strike puller with hammer.
   ⚠Do not use jaw-type pullers that grip the outer edge of the pulley. Use only bolt-in style harmonic balancer pullers.
5. 5

   Remove timing chain cover
   Disconnect coolant hoses from timing cover as needed. Remove timing cover bolts in sequence, noting that there are two different sizes (10mm and 8mm head bolts). Keep bolts organized by size and location. Carefully pry timing cover away from engine block using plastic pry tool at designated pry points. Remove timing cover and front crankshaft seal as an assembly. Clean all RTV sealant from engine block and timing cover mating surfaces using wire brush and solvent.
6. 6

   Verify timing alignment
   With timing cover removed, verify all timing marks are still correctly aligned: crankshaft keyway at 12 o'clock position, colored chain links aligned with marks on both camshaft sprockets, and crankshaft sprocket mark aligned with mark on engine block. Confirm alignment matches reference photos taken earlier. Do not proceed if timing marks have moved.
   ⚠️If timing marks are not aligned, do not continue. Determine cause of misalignment before proceeding.
7. 7

   Remove timing chain guides
   Remove the timing chain guide bolts securing the fixed chain guides to the engine block. There are typically two guides: one on the intake side and one on the exhaust side. Keep guides and bolts organized for reinstallation in original positions.
8. 8

   Remove timing chain tensioner
   Remove the timing chain tensioner mounting bolt. Note the position and orientation of the tensioner before removal. Carefully withdraw the tensioner assembly from the engine block, controlling it as spring pressure releases. Inspect the tensioner mounting hole in the block for debris or damage.
   ⚠Tensioner contains internal spring pressure. Support tensioner body while removing mounting bolt.
9. 9

   Install new timing chain tensioner
   Compress the new tensioner plunger and install the retaining pin or clip to hold it in the compressed position (new tensioners typically come with pin installed). Apply clean engine oil to the tensioner body and plunger. Install tensioner into engine block, ensuring proper orientation matches original position. Thread tensioner mounting bolt finger-tight, then torque to specification. Do not remove retaining pin yet.
10. 10

    Reinstall timing chain guides
    Install timing chain guides in their original positions. Apply threadlocker to guide bolts per manufacturer specification. Torque guide bolts to specification in a cross pattern if multiple bolts per guide.
11. 11

    Install timing cover and seal
    Install new crankshaft front seal into timing cover using seal driver. Apply continuous 2-3mm bead of RTV silicone to timing cover mating surface, circling all bolt holes on the inside. Apply small dab of RTV to corners where cover meets cylinder head. Install timing cover within 5 minutes of applying RTV. Install all timing cover bolts finger-tight first. Torque 8mm head bolts to their specification, then 10mm head bolts to their specification, following tightening sequence from center outward.
    ℹ️RTV requires specific cure time. Do not add oil or start engine for minimum 1 hour after assembly, or follow RTV manufacturer cure time.
    Torque spec

    Timing cover bolts22 Nm (16 lb-ft)
12. 12

    Release timing chain tensioner
    Remove the retaining pin or clip from the timing chain tensioner through the access point. You should feel or hear the tensioner plunger extend to apply proper tension to the timing chain. Verify chain has appropriate tension by gently pressing on chain between sprockets (slight deflection only).
13. 13

    Install crankshaft pulley
    Clean crankshaft snout and pulley hub thoroughly. Apply small amount of clean engine oil to crankshaft snout. Install crankshaft pulley, aligning keyway. Install new crankshaft pulley bolt. Hold crankshaft from rotating using holding tool. Torque crankshaft pulley bolt to specification.
    Torque spec

    Crankshaft pulley bolt215 Nm (159 lb-ft)
14. 14

    Rotate engine and verify timing
    Manually rotate crankshaft two complete revolutions clockwise using socket on crankshaft pulley bolt. Return to TDC position. Verify all timing marks align correctly: crankshaft pulley mark at TDC, camshaft sprocket marks aligned with cylinder head surface, and colored chain links aligned with sprocket marks. If timing marks do not align perfectly, timing chain installation is incorrect and must be corrected before proceeding.
    ⚠️Do not start engine if timing marks do not align after two rotations. Disassemble and correct timing chain installation.
15. 15

    Reinstall valve cover and accessories
    Install new valve cover gasket into valve cover groove. Clean valve cover mating surface on cylinder head. Position valve cover onto cylinder head. Install valve cover bolts and torque in sequence from center outward. Reinstall ignition coils and torque bolts. Reconnect ignition coil connectors and PCV hoses. Reinstall air conditioning compressor, alternator, drive belt tensioner, and drive belt. Verify belt routing is correct.

Reassembly

1. Reinstall air intake assembly and air filter housing
2. Reconnect all electrical connectors per labels and photos
3. Install engine cover
4. Install engine splash shield and undertray panels
5. Lower vehicle from jack stands
6. Reconnect negative battery cable
7. Fill engine with specified quantity of 0W-20 engine oil using new oil filter
8. Fill cooling system with specified Hyundai/Kia Long Life Coolant to proper level
9. Bleed cooling system per manufacturer procedure to remove air pockets

Verification

• Perform visual inspection of all work areas for loose bolts, disconnected hoses, or tools left in engine bay
• Start engine and verify it runs smoothly without abnormal noises, particularly rattling from timing chain area
• Check for oil leaks around timing cover, valve cover, and crankshaft pulley after engine reaches operating temperature
• Check for coolant leaks around timing cover connections
• Verify proper engine oil pressure on instrument cluster
• Allow engine to idle for 10 minutes, monitoring for unusual noises or leaks
• Test drive vehicle and verify normal engine operation under load and acceleration
• Re-check oil and coolant levels after test drive, top off if necessary
• Inspect for leaks again after test drive with engine warm

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