Sonata 2.0 16v

Hyundai Sonata 2.
0 16v 1993-1996
Timing belt: removal/installation
General
Before disconnecting the battery cable, check the audio system security code
Always check the timing marks before timing belt removal
(1.00)
Removal
Disconnect the battery
Remove the engine covers
Remove the ancillary drive belts
Remove the crankshaft pulley
Use a trolley jack to support the engine
Remove the right-hand engine support
Remove the coolant pump pulley
Remove the timing belt front covers
(2.00)
DataCar www.datacar-manualrepair.com
Hyundai Sonata 2.0 16v 1993-1996
General
(1.00)
Turn the crankshaft to TDC for cylinder 1

Align the timing marks
(1.00)
Removal
(2.00)
General
(1.00)
Remove the automatic tensioner

Remove the tensioner pulley
Remove the timing belt
Check the gearwheels, tensioner and idler pulley(s) for damage and wear
Removal
Balance shaft drive assembly:
Check the balance shaft timing marks
Loosen the balance shaft drive belt tensioner
(9.00)
(2.00)
General
(1.00)
Remove the balance shaft drive belt

Check the gearwheels, tensioner and idler pulley(s) for damage and wear
Installation
Balance shaft drive assembly:
Check the balance shaft timing marks
Fit the balance shaft drive belt
(4.00)
Removal
Remove
Note: thetension
Keep timing on
beltthe
front covers
timing belt
(2.00)
(8.00)
General
(1.00)
Push the tensioner pulley against the timing belt

Note: When tightening the tensioner, never rotate the tensioner pulley
Tighten the balance shaft drive belt tensioner (20 Nm)
(9.00)
Removal
Check
Removethethe
balance shaft
ancillary timing
drive beltsmarks
Check
Removethethe
balance shaft pulley
crankshaft drive belt tension
The
Use tension
a trolleyisjack
set at
to asupport
deflection
the of:
engine (5 - 7 mm)
(7.00)
(2.00)
General
(1.00)
Remove the plug

(13.00)
Removal
Lock the balance shaft by inserting a pin in the hole on the front left side of the cylinder block
Remove
(Ø 8 mm,the
L >right-hand
60 mm) engine support
(14.00)
(2.00)
General
(1.00)
If the pin cannot be inserted to the specified limit, turn the balance shaft 1 revolution clockwise
Compress the tensioner

(10.00)
Removal
Push the the
Remove piston and insert
ancillary drive abelts
suitable pin
Refit
Removethe automatic tensioner
the crankshaft pulley(20 - 25 Nm)
Fit
Usethe tensioner
a trolley jackpulley with bolt
to support finger-tight
the engine
Align
Removethe the
pinhole in the tensioner
right-hand pulley to the left of the bolt
engine support
Check
Remove thethe
timing beltpump
coolant markspulley
(1.00)
(2.00)
General
(1.00)
Fit the timing belt in the sequence as shown in the figure (A-> B-> C-> D-> E)
(5.00)
Removal
(2.00)
General
(1.00)
Turn the exhaust camshaft 1 tooth clockwise

Align the camshaft timing marks
Fit the timing belt on the left-hand camshaft gearwheel (F)
Turn the tensioner clockwise
Removal
Tighten the tensioner pulley
Turn the engine 1/4 rotation anti-clockwise
Turn the crankshaft to TDC for cylinder 1
Loosen the tensioner pulley
Use a special tool to adjust the timing belt tension (09244-28100)
Tighten the special tool
Use a torque wrench (2.6 - 2.8 Nm)
Tighten the tensioner pulley (45 - 55 Nm)
Use a special tool to adjust the timing belt tension (09244-28000)
(2.00)
(15.00)
General
(1.00)
Remove the special tools

Check the timing marks again
Unlock the balance shaft
Refit the plug
(13.00)
Removal
Unlock
Removethe
thetensioner
right-hand engine support
Rotate
Removethe
thecrankshaft clockwise
coolant pump pulleyby 2 turns
Align
Removethethe
timing marks
timing belt front covers
(2.00)
Wait for 15 minutes
Measure
Generalthe protrusion of the tensioner push rod from the housing end
Measurement
Before disconnecting
value the battery
(A: 3.8
cable,
- 4.5check
mm) the audio system security code
(3.00)
(1.00)
Fit both timing belt covers (10 - 12 Nm)

(2.00)
Removal
Fit the coolant pump (8 - 10 Nm)
(2.00)the crankshaft pulley (20 - 30 Nm)
Refit
Refit the ancillary drive belts
General
Beforethe
Refit disconnecting
right-hand engine
the battery
support
cable, check the audio system security code
Removecheck
Always the jack
the timing marks before timing belt removal
(1.00)
Refit the engine covers
Reconnect the battery
Torque settings
Tensioner body (bolts): (20 - 25 Nm)
Tensioner pulley: (45 - 55 Nm)
Balance shaft drive belt tensioner: (20 Nm)
Crankshaft pulley: (20 - 30 Nm)
Coolant pump pulley: (8 - 10 Nm)
Timing belt covers: (10 - 12 Nm)
Special tools
Socket wrench: (09244-28100)
(11.00)
Removal
Tensioner adjustment
Use a trolley tool: (09244-28000)
jack to support the engine
(12.00)
(2.00)
General
(1.00)
DataCar
Removal
(2.00)

Sonata 2.0 16v

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Hyundai Sonata 2.

Turn the crankshaft to TDC for cylinder 1

Remove the automatic tensioner

Remove the balance shaft drive belt

Push the tensioner pulley against the timing belt

Remove the plug

Compress the tensioner

Turn the exhaust camshaft 1 tooth clockwise

Remove the special tools

Fit both timing belt covers (10 - 12 Nm)

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