This procedure replaces the variable valve timing (VVT) actuator on the intake camshaft of the 2.5L I4 engine, requiring removal of the valve cover, timing chain cover, and timing components.

Warnings

Tools required

Parts

• VVT actuator (intake camshaft) × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• VVT solenoid O-ring × 1 — Use OEM specification
• Engine oil × 5 — Hyundai Genuine 0W-20

Fluids

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

Preparation

1. Ensure engine is completely cool to avoid burns from coolant
2. Disconnect negative battery terminal and wait 3 minutes
3. Remove engine cover by pulling upward on clips
4. Drain coolant into suitable container by opening radiator petcock and removing radiator cap
5. Raise and secure vehicle on jack stands
6. Remove right front wheel and inner fender splash shield for crankshaft access
7. Remove serpentine belt by rotating tensioner counterclockwise
8. Support engine from below with floor jack and remove right engine mount
9. Photograph or mark all timing marks on crankshaft, camshafts, and timing chain before disassembly

Procedure

1. 1

   Remove valve cover and accessories
   Disconnect ignition coil connectors and remove all four coils. Disconnect PCV hose, breather hose, and VVT solenoid connectors from valve cover. Remove valve cover bolts in reverse sequence (outside to inside) and carefully lift valve cover. Clean all gasket material from mating surfaces.
   Torque spec

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

   Remove crankshaft pulley
   Remove crankshaft pulley center bolt using breaker bar or impact wrench while holding crankshaft from rotating (use harmonic balancer holding tool or place transmission in gear with parking brake applied). Use harmonic balancer puller to remove pulley from crankshaft. Do not pry against timing cover.
   ⚠Do not use impact wrench during installation as crankshaft pulley bolt may be torque-to-yield. Check service manual for replacement requirements.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing chain cover
   Disconnect crankshaft position sensor connector. Remove all timing cover bolts noting their different lengths and locations. Carefully pry timing cover away from engine block using plastic pry points. Remove old gasket material and clean all sealing surfaces thoroughly. Inspect crankshaft front seal condition.
   ℹ️Cover bolts are different lengths. Mark or organize them by position for reassembly.
   Torque spec

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

   Verify and lock timing position
   Verify crankshaft is at TDC for cylinder #1 by confirming timing marks on crankshaft sprocket and camshaft sprockets align with marks on engine block and head. Install timing chain locking tool or insert locking pins to prevent chain movement. Confirm intake and exhaust cam lobes for cylinder #1 point upward at approximately 45 degrees from vertical.
   ⚠️Failure to properly lock timing will result in valve-to-piston contact and engine damage.
5. 5

   Release timing chain tension
   Remove timing chain tensioner bolt and extract tensioner assembly. The tensioner may be spring-loaded; control its removal. Inspect tensioner for wear or damage. Note the position of timing chain guide rails for reassembly reference.
   ⚠Spring-loaded tensioner may release suddenly. Keep clear of moving parts.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
6. 6

   Remove intake camshaft VVT actuator
   Identify intake camshaft (front camshaft). Hold camshaft stationary using wrench on the camshaft hex section behind the VVT actuator. Remove cam phaser bolt while preventing camshaft rotation. Carefully remove VVT actuator from camshaft and timing chain. Mark chain position relative to actuator before removal if locking tool not used.
   ⚠Do not drop actuator or allow chain to slip off sprockets. Support timing chain with wire if necessary.
   Torque spec

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

   Inspect and prepare new VVT actuator
   Inspect camshaft nose, timing chain condition, and chain guide rails for wear. Verify new VVT actuator matches original part number and is correct for intake position. Check actuator rotates smoothly by hand and oil passages are clear. Pre-fill new actuator with clean engine oil through supply passages.
   ℹ️Pre-filling actuator prevents dry start and potential damage during initial engine operation.
8. 8

   Install new VVT actuator
   Align new VVT actuator with timing chain and slide onto intake camshaft nose, ensuring dowel pin on camshaft engages slot in actuator. Verify timing marks still align correctly. Apply medium-strength threadlocker to cam phaser bolt threads. Hold camshaft stationary with wrench on hex section and install cam phaser bolt. Torque to specification.
   ⚠️Verify all timing marks are correctly aligned before tightening. Incorrect timing will destroy engine.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
9. 9

   Reinstall timing chain tensioner
   Compress timing chain tensioner using bench vise and install locking pin or clip to hold it compressed. Install tensioner into engine block and torque mounting bolt to specification. Remove locking pin/clip to apply tension to timing chain. Verify chain has proper tension and timing marks remain aligned.
   ⚠Ensure tensioner pin is removed after installation. Failure to remove will cause timing chain slack and engine damage.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
10. 10

    Reinstall timing chain cover
    Install new crankshaft front seal into timing cover if removed or damaged. Apply thin bead of RTV silicone to timing cover mating surface per factory pattern (thin bead around bolt holes and oil passages). Position new gasket and install timing cover, ensuring crankshaft seal properly seats on crankshaft. Install all cover bolts finger-tight, then torque in sequence from center outward.
    ℹ️Allow RTV to cure for 30 minutes before adding coolant or oil.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
11. 11

    Reinstall crankshaft pulley
    Clean crankshaft nose and pulley hub thoroughly. Slide crankshaft pulley onto crankshaft, ensuring keyway aligns. Install crankshaft pulley bolt and torque to specification while preventing crankshaft rotation. If bolt is torque-to-yield type, replace with new bolt and follow angle torque specification if required.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
12. 12

    Reinstall valve cover
    Install new valve cover gasket into valve cover groove, ensuring proper seating around all bolt holes. Position valve cover onto cylinder head and install all bolts finger-tight. Torque valve cover bolts in sequence (center outward) to specification. Reconnect VVT solenoid connector, PCV hose, and breather hose. Reinstall ignition coils and connectors.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    VVT Solenoid Bolt10 Nm (7 lb-ft)
13. 13

    Reinstall accessories and refill fluids
    Reinstall right engine mount and torque to specification. Install serpentine belt following routing diagram on belt tensioner or radiator support. Reinstall splash shield and wheel, torquing lug nuts to specification. Refill engine with specified oil quantity. Refill cooling system with proper coolant mixture. Reconnect negative battery terminal.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

Reassembly

1. Double-check all timing marks are properly aligned before starting engine
2. Verify all electrical connectors are fully seated and secured
3. Confirm no tools or parts are left in engine compartment
4. Check all fluid levels are correct before starting

Verification

• Start engine and listen for abnormal noises, particularly rattling from timing chain area
• Monitor for oil leaks around valve cover and timing chain cover while engine idles
• Check for coolant leaks around timing cover and hose connections
• Verify VVT system operation by scanning for diagnostic trouble codes related to VVT performance
• Test drive vehicle and confirm smooth operation with no check engine light, hesitation, or rough idle
• After test drive, recheck oil level and top off if necessary
• Scan for any stored timing-related fault codes using OBD-II scanner

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