Replace the timing chain, guides, tensioners, and related components on the 2.5L I4 engine to restore proper valve timing and eliminate timing chain noise or stretch.

Warnings

Tools required

Parts

• Timing chain kit (chain, guides, tensioners) × 1 — Use OEM Hyundai 2.5L timing chain kit
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Valve cover bolt grommets × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• Oil pan gasket (if disturbed) × 1 — Use OEM specification
• Engine oil and filter × 1 — 0W-20 synthetic
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant (Hyundai approved) × 1 — Use OEM specification
• Coolant × 1 — Hyundai/Kia Long Life Coolant

Fluids

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

Preparation

1. Verify timing chain replacement is necessary by checking for chain stretch, noise, or fault codes P0016/P0017/P0018
2. Obtain official Hyundai service manual for 2.5L Smartstream engine timing marks and bolt sequences
3. Disconnect negative battery cable and wait 3 minutes for airbag system to discharge
4. Raise and support vehicle on jack stands at all four corners
5. Remove engine splash shields and undercovers
6. Drain engine oil completely and remove oil filter
7. Drain cooling system into appropriate container
8. Remove front wheels for access to crankshaft pulley
9. Install engine support fixture across engine bay or attach hoist to engine lifting eyes
10. Remove upper engine cover and air intake assembly
11. Disconnect all electrical connectors from valve cover (ignition coils, VVT solenoids, cam sensors)
12. Label and photograph all vacuum lines and wiring harness routing

Procedure

1. 1

   Remove Accessory Drive Components
   Remove serpentine belt by releasing tensioner. Remove belt tensioner and idler pulleys. Disconnect crankshaft position sensor connector and set aside. Support engine weight with fixture or hoist before proceeding.
2. 2

   Remove Engine Mount and Crankshaft Pulley
   Remove right-side engine mount to access timing cover. Use crankshaft holding tool or impact wrench to remove crankshaft pulley bolt (left-hand thread rotation to loosen). Remove crankshaft pulley. This bolt is often torque-to-yield; inspect and replace if specified in service manual.
   ⚠Crankshaft pulley bolt requires significant torque to remove. Ensure vehicle is securely supported and cannot roll.
3. 3

   Remove Valve Cover
   Remove ignition coils and set aside. Disconnect PCV hose and breather hoses from valve cover. Remove valve cover bolts in reverse of tightening sequence (consult service manual). Carefully lift valve cover, breaking seal with plastic mallet taps if necessary. Do not pry on sealing surfaces.
   ℹ️Mark valve cover bolt locations if different lengths are used.
4. 4

   Rotate Engine to TDC Cylinder #1
   Rotate crankshaft clockwise using 19mm socket on crankshaft bolt until cylinder #1 is at Top Dead Center on compression stroke. Verify timing marks: crankshaft keyway at 12 o'clock, camshaft timing marks aligned with cylinder head surface, timing chain colored links aligned with camshaft sprocket marks. Take multiple photographs from different angles.
   ⚠️Confirm TDC position by checking that both intake and exhaust valves for cylinder #1 are closed (rocker arms loose). If either valve is open, rotate one full revolution.
5. 5

   Remove Timing Cover
   Disconnect VVT solenoid connectors and camshaft position sensors. Remove timing cover bolts, noting 6mm, 8mm, and 10mm bolt locations per service manual diagram. Carefully separate timing cover from engine block, tapping gently with plastic mallet if needed. Remove old gasket material and RTV from all sealing surfaces using scraper. Clean surfaces with RTV remover spray and ensure completely dry.
   ⚠Do not damage aluminum sealing surfaces. Use plastic scrapers on machined surfaces.
   Torque spec

   Timing Cover Bolts12 Nm (9 lb-ft)
6. 6

   Lock Timing Chain Tensioner and Remove Chain
   Compress timing chain tensioner and insert retaining pin or clip to hold in compressed position. Remove tensioner bolt and remove tensioner assembly. Remove timing chain guides by removing guide bolts. Hold camshafts stationary using wrench on hex section and remove camshaft sprocket bolts. Remove both camshaft sprockets and timing chain as an assembly. Remove crankshaft sprocket if replacement is required.
   ⚠Support camshaft sprockets when removing bolts to prevent chain from binding or falling into engine.
   Torque spec

   Timing Chain Tensioner25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)

   Camshaft Sprocket Bolts80 Nm (59 lb-ft)
7. 7

   Inspect and Replace Components
   Inspect timing chain guides for wear grooves, cracks, or material loss exceeding 1mm depth. Inspect tensioner for leakage or damage. Inspect camshaft and crankshaft sprockets for wear or damage to teeth. Replace all guides, tensioners, and chain even if wear appears minimal. Inspect oil pump drive chain and sprocket if accessible; replace if wear is evident.
8. 8

   Install Crankshaft Sprocket and Guides
   Install crankshaft sprocket with timing mark facing outward. Install timing chain idler sprocket if equipped. Install fixed timing chain guides and tighten guide bolts to specification. Ensure guides are properly seated in locating grooves.
   ℹ️Crankshaft sprocket typically has alignment key or flats to ensure correct orientation.
   Torque spec

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

   Install Timing Chain and Camshaft Sprockets
   Verify crankshaft is still at TDC position. Route new timing chain around crankshaft sprocket with colored link aligned to crankshaft timing mark. Route chain through guides and around camshaft sprocket positions. Install camshaft sprockets onto camshafts, aligning dowel pins. Ensure colored chain links align with camshaft sprocket timing marks per service manual. Hold camshafts with wrench on hex and install camshaft sprocket bolts finger-tight. Verify all timing marks are perfectly aligned before proceeding.
   ⚠️Triple-check all timing mark alignment before tightening any bolts. One tooth off will cause engine damage.
10. 10

    Install Tensioner and Torque Components
    Compress new timing chain tensioner and insert retaining pin. Install tensioner and tighten tensioner bolt to specification. Hold camshafts stationary and torque camshaft sprocket bolts to specification. Remove tensioner retaining pin to apply tension to chain. Rotate crankshaft two full revolutions clockwise and verify all timing marks realign perfectly at TDC. If marks do not align, remove chain and repeat installation.
    ⚠️If timing marks do not realign after two revolutions, do not proceed. Chain is incorrectly installed.
    Torque spec

    Timing Chain Tensioner25 Nm (18 lb-ft)

    Camshaft Sprocket Bolts80 Nm (59 lb-ft)
11. 11

    Install New Timing Cover Seal and Gasket
    Install new crankshaft front seal into timing cover using seal driver, ensuring seal is flush and square. Apply thin bead of Hyundai-approved RTV silicone to timing cover mating surface per service manual pattern (typically at block-to-oil pan joints). Install new timing cover gasket onto engine block alignment dowels.
    ℹ️RTV must be applied in correct pattern and thickness. Too much will cause leaks; too little will also leak.
12. 12

    Install Timing Cover
    Carefully position timing cover onto engine block, aligning over dowel pins and crankshaft seal over crankshaft snout. Install all timing cover bolts finger-tight, ensuring correct bolt sizes in correct locations (6mm, 8mm, 10mm per service manual). Tighten bolts in sequence specified in service manual: 6mm bolts to 10 Nm, 8mm bolts to 25 Nm, 10mm bolts to 45 Nm. Reinstall VVT solenoids and camshaft position sensors.
    ⚠Tightening sequence is critical to prevent cover warping and oil leaks. Follow service manual exactly.
    Torque spec

    Timing Cover Bolts12 Nm (9 lb-ft)
13. 13

    Install Crankshaft Pulley and Valve Cover
    Install crankshaft pulley onto crankshaft, ensuring keyway alignment. Install crankshaft pulley bolt and torque to 180 Nm using holding tool or impact wrench. If bolt is torque-to-yield, follow angle torque procedure per service manual. Install new valve cover gasket and grommets. Apply small dab of RTV at camshaft cap corners if specified. Install valve cover and tighten bolts in sequence from center outward to 10 Nm. Reinstall ignition coils, PCV valve, and breather hoses.
    ℹ️Some Hyundai engines require specific RTV application at camshaft cap areas. Verify in service manual.
14. 14

    Reinstall Accessories and Fill Fluids
    Reinstall right engine mount and torque to specification. Install accessory drive belt tensioner, idler pulleys, and serpentine belt. Reconnect crankshaft position sensor. Install new oil filter and drain plug with new crush washer, torquing drain plug to 35 Nm. Fill engine with 5.0 quarts of Hyundai Genuine 0W-20 oil. Refill cooling system with Hyundai/Kia Long Life Coolant to proper level. Reconnect all electrical connectors and vacuum lines per photos taken during disassembly.
    ℹ️Verify coolant fill procedure in service manual. Some engines require air bleeding procedure.
15. 15

    Initial Start and Timing Verification
    Reconnect battery negative cable. Turn ignition to ON position without starting for 10 seconds to prime fuel system. Repeat 3 times. Start engine and immediately verify oil pressure. Allow engine to idle and listen for abnormal noises. Check for oil, coolant, or vacuum leaks. Use scan tool to check for fault codes. Verify camshaft and crankshaft position sensor correlation values are within specification (typically ±5 degrees). If codes P0016/P0017/P0018 appear, timing is incorrect and must be rechecked.
    ⚠️If any abnormal noise is heard on startup, immediately shut off engine and recheck timing chain installation.
    ⚠Engine may run roughly for first 30-60 seconds while VVT system relearns positions. This is normal if no fault codes appear.

Reassembly

1. Reinstall engine splash shields and undercovers
2. Reinstall front wheels and torque lug nuts to specification
3. Lower vehicle and remove engine support fixture
4. Reinstall upper engine cover and air intake assembly
5. Perform final check of all fluid levels
6. Verify all electrical connectors are properly seated
7. Clear any adaptation values using scan tool if available

Verification

• Start engine and verify no oil leaks from timing cover, valve cover, or oil pan
• Verify no coolant leaks from timing cover or water pump area
• Check for proper oil pressure on instrument cluster or scan tool (should be above 20 psi at idle when warm)
• Listen for timing chain noise - should be completely silent at idle and during acceleration
• Scan for fault codes - P0016, P0017, P0018 indicate timing correlation errors and require immediate attention
• Verify camshaft correlation values on scan tool are within ±5 degrees of specification
• Test drive vehicle through full RPM range and verify smooth operation with no hesitation or misfires
• Recheck oil level after test drive and top off if necessary (timing chain operation may circulate additional oil)
• Monitor engine for next 100 miles for any leaks, noises, or performance issues

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