Santa FE 2008 2.7L

2008 Hyundai Santa Fe SE
2008 ENGINE Engine Mechanical System (G6EA-GSL 2.7) - Santa Fe
2008 ENGINE
Engine Mechanical System (G6EA-GSL 2.7) - Santa Fe
GENERAL
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description Specifications Limit

General
Type V-type, DOHC

Number of cylinder 6
Bore 86.7mm (3.4134in.)
Stroke 75mm (2.9528in.)

Total displacement 2,656cc
Compression ratio 10.4
Firing order 1-2-3-4-5-6
Valve timing
Opens (ATDC) 4° ~ -56°
Intake valve
Closes (ABDC) 60° ~ 0°
Opens (BBDC) 46°

Exhaust valve
Closes (ATDC) 10°
Cylinder head
0.05mm
Flatness of gasket surface 0.03mm (0.0012in.) or less
(0.0020in.)
Flatness of
Intake 0.15mm (0.0059in.) or less
manifold
Exhaust 0.15mm (0.0059in.) or less
mounting
Camshaft
LH Intake 44.5mm (1.7520in.)
Camshaft Exhaust 44.5mm (1.7520in.)
Cam height
RH Intake 44.5mm (1.7520in.)
Camshaft Exhaust 44.5mm (1.7520in.)
LH Intake 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)

Journal outer Camshaft Exhaust 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)
diameter RH Intake 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)
Camshaft Exhaust 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)
Bearing oil Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in.)

clearance Exhaust 0.030 ~ 0.057mm (0.0012 ~ 0.0022in.)
End play 0.1 ~ 0.2mm (0.0039 ~ 0.0079in.)
Valve
viernes, 19 de febrero de 2021 11:31:382 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Intake 110.1mm (4.3346in.)
Valve length
Exhaust 111.1mm (4.3740in.)
Stem outer Intake 5.965 ~ 5.980mm (0.2348 ~ 0.2354in.)
diameter Exhaust 5.950 ~ 5.965mm (0.2343 ~ 0.2348in.)
Face angle 45° ~ 45.5°
Thickness of
Intake 1.0mm (0.0394in.)
valve head
Exhaust 1.3mm (0.0512in.)
(margin)
0.10mm
Intake 0.020 ~ 0.050mm (0.0008 ~ 0.0020in.) (0.0039in.) or
Valve stem to
less
valve guide
0.13mm
clearance
Exhaust 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.) (0.0051in.) or
less
Valve guide
Intake 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.)

Inner diameter
Exhaust 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.)
Intake 45.8 ~ 46.2mm (1.8031 ~ 1.8189in.)
Length
Exhaust 46.8 ~ 47.2mm (1.8425 ~ 1.8583in.)
Valve spring
Free length 46.8mm (1.8425in.)
180.5 ~ 199.5N (18.4 ~ 20.3Kgf, 40.6 ~
Height: 35mm
Load 44.8lb)
Height: 26.5mm 342 ~ 378N (34.9 ~ 38.6Kgf, 76.9 ~ 85.1lb)
Out of squareness 1.5° or less
MLA (Mechanical Lash Adjuster)

MLA outer Intake 29.964 ~ 29.980mm (1.1797 ~ 1.1803in.)
diameter Exhaust 29.964 ~ 29.980mm (1.1797 ~ 1.1803in.)
Cylinder head
Intake 30.000 ~ 30.025mm (1.1811 ~ 1.1821in.)
tappet bore inner

Exhaust 30.000 ~ 30.025mm (1.1811 ~ 1.1821in.)
diameter
0.07mm
Intake 0.020 ~ 0.061 mm (0.0008 ~ 0.0024in.) (0.0027in.) or
MLA to tappet less
bore clearance 0.07mm
Exhaust 0.020 ~ 0.061 mm (0.0008 ~ 0.0024in.) (0.0027in.) or
less
Valve clearance
0.20 ~ 0.40mm
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.) (0.0078 ~
0.0157in.)
Cylinder block
Cylinder bore 86.7 ~ 86.73mm (3.4134 ~ 3.4146in.)
Less than 0.03mm (0.0012in.) [Less than

Flatness of gasket surface
0.02mm (0.0008in.) / 150 x 150]
Piston
Piston outer diameter 86.67 ~ 86.70mm (3.4122 ~ 3.4134in.)
Piston to cylinder clearance 0.02 ~ 0.04mm (0.0008 ~ 0.0020in.)
No. 1 ring groove 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.)

Ring groove width No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)
Piston O.S. 0.25mm (0.0098in.) 0.50mm (0.0197in.)

Piston ring
0.1mm
No. 1 ring 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in.)
(0.0039in.)
0.1mm
Side clearance No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
(0.0039in.)
0.2mm
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
(0.0079in.)
0.6mm
No. 1 ring 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
(0.0236in.)
0.7mm
End gap No. 2 ring 0.30 ~ 0.45mm (0.0118 ~ 0.0177in.)
(0.0275in.)
0.8mm
Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in.)
(0.0315in.)
Piston ring O.S. 0.25mm (0.0098in.) 0.50mm (0.0197in.)

Piston pin
Piston pin outer diameter 21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
Piston pin hole inner diameter 21.014 ~ 21.023mm (0.8273 ~ 0.8277in.)

Piston pin hole interference 0.011 ~ 0.018mm (0.0004 ~ 0.0007in.)
Connecting rod small end inner diameter 20.974 ~ 20.985mm (0.8257 ~ 0.8262in.)
Connecting rod small end hole clearance -0.033 ~ -0.016mm (0.0013 ~ 0.0006in.)
Connecting rod
Connecting rod big end inner diameter 51.000 ~ 51.018mm (2.0079 ~ 2.0086in.)
Connecting rod bearing oil clearance 0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)
0.4mm
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)
(0.0157in.)
Crankshaft
Main journal outer diameter 61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Pin journal outer diameter 47.982 ~ 48.000mm (1.8891 ~ 1.8898in.)
Main bearing oil clearance 0.004 ~ 0.022mm (0.0002 ~ 0.0009in.)
0.30mm
End play 0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
(0.0118in.)
Oil pump
Relief valve opening pressure 2
490.33 ~ 588.40kPa (5.0 ~ 6.0kgf/cm , 71.12
~ 85.34 psi)
Engine oil
Drain & Refill;
Oil quantity (Total) 4.8L (5.07U.S.qts,4.22lmp.qts)
4.5L
3.4~4.2L
Oil quantity (Oil pan)
(3.59~4.44U.S.qts,2.99~3.70lmp.qts)
Oil quantity (Oil filter) 0.3L (0.32U.S.qts,0.26lmp.qts)
Oil quality Above SJ or SL
2
130kPa (1.32kgf/cm , 18.77psi) [at 1000rpm,
Oil pressure
110°C (230°F))
Cooling system
Cooling method Forced circulation with electrical fan
8.2~8.3L
Coolant quantity
(8.66~8.77U.S.qts,7.22~7.30lmp.qts)
Type Wax pellet type

Opening temperature 82±2°C (179.6±35.6°F)
Thermostat Fully opened
95°C (203°F)
temperature
Full lift 10mm (0.3937in.) or more
2
Main valve opening 93.16 ~ 122.58kpa (0.95 ~ 1.25 kg/cm ,
pressure 13.51 ~ 17.78psi)
Radiator cap 2
Vacuum valve 0.98 ~ 4.90 kpa (0.01 ~ 0.05 kg/cm , 0.14 ~
opening pressure 0.71 psi)
Engine coolant temperature sensor
Type Thermister type
20°C (68°F) 2.31 ~ 2.59 kohms
Resistance
80°C (176°F) 0.3222 kohms
TIGHTENING TORQUE
TIGHTENING TORQUE
Item Quantity Nm kgf.m lb-ft
Oil seal case bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Main bearing cap bolt (M10) 8 26.5~32.4+90°+5° 2.7~3.24+90°+5° 19.5~23.7+90°+5°
Main bearing cap bolt (M8) 8 12.7~18.6+90°+5° 1.3~1.9+90°+5° 9.4~13.7+90°+5°
Rear plate bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil pump case bolt (8x25) 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Oil relief plug 1 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2
Oil filter bracket bolt (8x35) 4 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Oil filter bracket bolt (8x65) 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Oil filter insert 1 44.1 ~ 53.9 4.5~ 5.5 32.5~ 39.8
Timing belt cover bolt 21 9.8 ~ 11.8 1.0~ 1.2 7.2~ 8.7
Upper oil pan bolt (8x22) 15 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Upper oil pan bolt (163.5mm) 1 4.9 ~ 6.9 0.5~ 0.7 3.6~ 5.1
Upper oil pan bolt (154.5mm) 1 4.9 ~ 6.9 0.5~ 0.7 3.6~ 5.1
Lower oil pan bolt 11 9.8 ~ 11.8 1.0~ 1.2 7.2~ 8.7
Oil drain plug 1 34.3 ~ 44.1 3.5~ 4.5 25.3~ 32.5
Engine support bracket bolt (10x94) 1 58.8 ~ 68.6 6.0~ 7.0 43.4~ 50.6
Engine support bracket bolt (10x102.5) 2 58.8 ~ 68.6 6.0~ 7.0 43.4~ 50.6
Camshaft bearing cap bolt (6x38) 24 10.8 ~ 12.7 1.1~ 1.3 8.0~ 9.4
Camshaft bearing cap bolt (8x38) 12 20.6 ~ 25.5 2.1~ 2.6 15.2~ 18.8
Cylinder head bolt 16 24.5 + 60°+ 45° 2.5 + 60°+ 45° 18.1 +60°+45°
Cylinder head cover bolt 22 7.8 ~ 9.8 0.8~ 1.0 5.8~ 7.2
Crankshaft pulley bolt 1 166.7 ~ 176.5 17.0~ 18.0 123.0~ 130.2
Drive plate bolt 8 71.6 ~ 75.5 7.3~ 7.7 52.8~ 55.7
Connecting rod bearing cap bolt 12 19.6 ~ 90° 2.0 ~ 90° 14.5 ~ 90°
OCV (Oil Control Valve) bolt 2 7.8 ~ 9.8 0.8~ 1.0 5.8~ 7.2
CVVT & exhaust cam sprocket bolt 4 66.7 ~ 78.5 6.8~ 8.0 49.2~ 57.9
Timing chain auto tensioner bolt 4 10.8 ~ 12.7 1.1~ 1.3 8.0~ 9.4
Camshaft sprocket bolt 2 88.3 ~ 107.9 9.0 ~ 11.0 65.1~ 79.6
Timing belt idler bolt 1 49.0 ~ 58.8 5.0~ 6.0 36.2~ 43.4
Timing belt tensioner bolt 2 19.6 ~ 26.5 2.0~ 2.7 14.5~ 19.5
Timing belt tensioner arm bolt 1 34.3 ~ 53.9 3.5~ 5.5 25.3~ 39.8
Water pump bolt (8x20) 3 14.7 ~ 21.6 1.5~ 2.2 10.8~ 15.9
Water pump bolt (8x25) 4 14.7 ~ 21.6 1.5~ 2.2 10.8~ 15.9
Drive belt idler bolt 1 34.3 ~ 53.9 3.5~ 5.5 25.3~ 39.8
Drive belt tensioner bolt 1 34.3 ~ 53.9 3.5~ 5.5 25.3~ 39.8
Water inlet pipe bolt 1 16.7 ~ 19.6 1.7~ 2.0 12.3~ 14.5
Water temp, control assembly nut 4 29.4 ~ 41.2 3.0~ 4.2 21.7~ 30.4
Oil level gauge bolt 1 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Oil screen bolt 2 14.7 ~ 21.6 1.5~ 2.2 10.8~ 15.9
Water outlet fitting bolt 3 16.7 ~ 19.6 1.7~ 2.0 12.3~ 14.5
Water inlet fitting bolt 2 16.7 ~ 19.6 1.7~ 2.0 12.3~ 14.5
Water inlet fitting nut 1 16.7 ~ 19.6 1.7~ 2.0 12.3~ 14.5
Surge tank bolt (8x28) 3 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Surge tank bolt (8x80) 2 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Surge tank nut 2 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Intake manifold bolt 4 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Intake manifold nut 4 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4

Surge tank bracket bolt 2 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4
Exhaust manifold bolt 14 29.4 ~ 34.3 3.0~ 3.5 21.7~ 25.3
6 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9

Front muffler bolt 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
COMPRESSION PRESSURE INSPECTION
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.
1. Warm up the engine until the normal operating temperature becoming 80~95°C (176~203°F).
2. Remove the surge tank.
3. Remove the ignition coil connectors (A) and ignition coils (B).
Fig. 1: Identifying Ignition Coil Connectors And Ignition

Coils Courtesy of HYUNDAI MOTOR CO.
4. Using a 16mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.
1. Insert a compression gauge into the spark plug hole.
2. Open the throttle fully.
3. With the fully-open throttle in cranking, measure the compression pressure.
NOTE: Always use a fully charged battery to get the engine speed of 250
rpm or more.
Repeat steps 1) through 3) for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
2
Compression pressure: 1,176.79kPa (12.0kgf/cm , 170.68psi) - 200 ~ 250rpm
2
Minimum pressure: 1,029.69kPa (10.5kgf/cm , 149.34psi)
2
Difference between cylinders: 98.07kPa (1.0kgf/cm , 14.22psi)
4. If the compression pressure in 1 or more cylinders is lower than the specification above, pour a
small amount of engine oil into the cylinder through the spark plug hole, repeat the steps (1) through (3) for the
cylinder and measure the pressure again.
If adding oil increases the pressure, the piston rings or cylinder bores might be worn
or damaged.
If the pressure doesn't increase, a valve may be sticking or seating may be improper, or
there may be leakage from the gasket.
6. Reinstall the spark plugs.
7. Install the ignition coils and connect ignition coil connectors.
8. Install the surge tank.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature : 20°C±5°C (59~77°F)) and cylinder head is installed on the
cylinder block.
1. Remove the engine cover.

2. Remove air cleaner assembly.
3. Remove the surge tank.
4. Remove the cylinder head cover.
1. Disconnect the ignition coil connector and remove the ignition coil.
2. Remove the cylinder head cover.
Fig. 2: Identifying Cylinder Head Cover
Courtesy of HYUNDAI MOTOR CO.
5. Set the piston of the No.1 cylinder to TDC (Top Dead Center) position.
1. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the timing
chain cover.
2. Check that the timing marks on the camshaft sprocket are in a straight line with the rocker cover
mark for No. 1 cylinder TDC as shown in the illustration.
Fig. 3: Identifying Timing Marks On Camshaft

Sprocket Courtesy of HYUNDAI MOTOR CO.
NOTE: If not, turn the crankshaft one revolution clockwise.
6. Inspect the intake and the exhaust valve clearance.

1. With No. 1 cylinder at TDC the valve clearance can be measured as shown below.
Fig. 4: Identifying Intake And Exhaust Valve Clearance
Measurement method.
Using a thickness gauge, measure the clearance between the tappet and the base circle
of camshaft.
Record the out-of-specification valve clearance measurements. They will be used later
to determine the required adjusting tappet for replacement.
Specification
Limit (Engine coolant temperature : 20°C [68°F])
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
2. Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing
mark "T" of the timing chain cover.
3. With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its
clearance are as shown below.
Fig. 5: Identifying Intake And Exhaust Valve

Clearance Courtesy of HYUNDAI MOTOR CO.
7. Adjust the intake and the exhaust valve clearances.

1. Set the piston of the No. 1 cylinder to the TDC/position.
2. Remove the timing belt.
3. Remove the camshaft bearing caps (A, B).
Fig. 6: Identifying Camshaft Bearing Caps

4. Remove the camshaft assembly.

5. Remove MLA (Mechanical Lash Adjusters.
6. Measure the thickness of the removed tappet using a micrometer.
Fig. 7: Measuring Thickness Of Tappet Using Micrometer

7. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm (0.0079in.)]
Exhaust: N = T + [A - 0.30mm (0.0118in.)]
8. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Tappets are available with 41 different size increments of 0.015mm

(0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.)
9. Place a new tappet on the cylinder head.
NOTE: Apply engine oil on the periphery surface of the selected tappet.
10. Install the intake and exhaust camshafts.

11. Install the bearing caps.
12. Install the timing belt.
13. Turn the crankshaft two revolutions in the operating direction (clockwise) and realign crankshaft
sprocket and camshaft sprocket timing marks (A).
14. Recheck the valve clearance.
Specification (Engine coolant temperature: 20°C[68°F])
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust: 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom Suspect area Remedy

Replace the crankshaft and bearings
Worn crankshaft bearings. Loose or as required.
improper engine drive plate. Repair or replace the drive plate as
Engine misfire with required.
abnormal internal Worn piston rings. (Oil consumption may Inspect the cylinder for a loss of
lower engine noises. or may not cause the engine to misfire.) compression.
Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings
as required.
Stuck valves. (Carbon buildup on the valve Repair or replace as required.
stem)
Engine misfire with
abnormal valve train Excessive worn or mis-aligned timing Replace the timing chain and
chain. sprocket as required.
noise.
Replace the camshaft and valve
Worn camshaft lobes.
lifters.
Faulty cylinder head gasket and/or Inspect the cylinder head and
cranking or other damage to the engine block for damage to the

cylinder head and engine block coolant passages and/or a faulty
Engine misfire with
cooling system. head gasket.
coolant consumption.
Coolant consumption may or may not Repair or replace as required.
cause the engine to overheat.
Worn valves, guides and/or valve stem oil Repair or replace as required.
seals.
Engine misfire with
excessive oil Inspect the cylinder for a loss
Worn piston rings. (Oil consumption may
consumption. of compression.
or may not cause the engine to misfire)
Drain the oil.
Incorrect oil viscosity.
Engine noise on start- Install the correct viscosity oil.
up, but only lasting a
Inspect the thrust bearing and
few seconds.
Worn crankshaft thrust bearing. crankshaft.
Low oil pressure. Repair or replace as required.

Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and
damaged sprocket teeth. sprockets.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as
required.
Upper engine noise,
Inspect the camshaft lobes.
regardless of engine
Worn camshaft lobes.
speed. Replace the timing camshaft
and valve lifters as required.
Inspect the valves and valve guides,

Worn valve guides or valve stems.
then repair as required.
Stuck valves. Carbon on the valve stem or Inspect the valves and valve guides,
valve seat may cause the valve to stay open. then repair as required.
Worn drive belt, idler, tensioner and
Replace as required.
bearing.
Low oil pressure. Repair as required.
Loose or damaged drive plate. Repair or replace the drive plate.

Inspect the oil pan.
Damaged oil pan, contacting the oil pump
Inspect the oil pump screen.
screen.
Oil pump screen loose, damaged or Inspect the oil pump screen.
restricted.
Excessive piston-to-cylinder bore
Inspect the piston, piston pin
clearance.
and cylinder bore.
Repair as required.
Inspect the piston, piston pin

Excessive piston pin-to-piston clearance. and the connecting rod.
Inspect the following components and

repair as required.
Excessive connecting rod bearing clearance

The connecting rod bearings.
The connecting rods.
Lower engine noise,
The crankshaft pin journals.
regardless of engine
speed. Inspect the following components,
and repair as required.
Excessive crankshaft bearing clearance.
The crankshaft bearings.
The crankshaft main journals.
The cylinder block.
Verify the piston pins and
Incorrect piston, piston pin and connecting connecting rods are installed
rod installation correctly.
Repair as required.
Low oil pressure Repair or replace as required.
Inspect the following components and

repair as required :
Excessive connecting rod bearing
The connecting rod bearings.
clearance.
The connecting rods.
Engine noise under
The crankshaft.
load.
Inspect the following components,
and repair as required.
Excessive crankshaft bearing clearance.

The crankshaft bearings.
The crankshaft main journals.
The cylinder block.
1. Remove spark plugs and check
for fluid.
Hydraulically locked cylinder.
2. Inspect for broken head gasket.
Coolant/antifreeze in cylinder. 3. Inspect for cracked engine
block or cylinder head.
Oil in cylinder.
4. Inspect for a sticking fuel
Fuel in cylinder.
injector and/or leaking fuel
regulator.
Broken timing chain and/or timing chain 1. Inspect timing chain and gears.
and/or timing chain gears.
2. Repair as required.
Material in cylinder.
1. Inspect cylinder for damaged
components and/or foreign
Broken valve
Engine will not crank- materials.
crankshaft will not Piston material
rotate. 2. Repair or replace as required.
Foreign material
1. Inspect crankshaft and
Seized crankshaft or connecting rod
connecting rod bearing.
bearings.
1. Inspect connecting rods.
Bent or broken connecting rod.
1. Inspect crankshaft.
Broken crankshaft.
SPECIAL TOOLS
SPECIAL TOOLS CHART

Tool (Number and name) Illustration Use
Crankshaft front oil seal installer

Installation of the front oil seal
(09214-33000)
Torque angle adapter (09221- Installation of bolts & nuts

4A000) needing an angular method
Valve stem seal remover (09222-

Removal of the valve stem seal
29000)
Valve stem seal installer (09222- Installation of the valve stem

22001) seal
Camshaft oil seal installer (09214- Installation of the camshaft oil

21000) seal
Removal and installation of the

intake or exhaust valves.
Valve spring compressor & holder
(09222-3K000) (09222-3C300)
A. 09222-3K000
B. 09222-3C300 (holder)
Crankshaft rear oil seal installer Installation of the crankshaft

(09231-33000) rear oil seal
Oil pan remover (09215-3C000) Removal of oil pan
Valve guide installer (09221- Removal and installation of the

3F100 A/B) valve guide
ENGINE BLOCK
ENGINE MOUNTS
DESCRIPTION
Semi-active mounting (it can also be called 'Electronic Controlled Mounting (ECM)'), unlike hydraulic
mountings before, is a controllable hydraulic mounting which gives a high damping value in driving and also
reduce violation with a low damping value and a spring coefficient at idle. This system is composed of a
power control module (PCM), solenoid valve and a diaphragm for ON/OFF in it.
At idle, the power control module (PCM) receives a RPM signal and give it to the solenoid valve. As the
valve opens or closes, vacuum pressure in the intake system goes to the diaphragm for opening the orifice. By
opening the orifice, the mounting has a low damping value and a low spring coefficient for reducing viblation.
OPERATION
Fig. 8: Electronic Controlled Mounting (ECM) - System

Diagram Courtesy of HYUNDAI MOTOR CO.
Fig. 9: Electronic Controlled Mounting (ECM) - Circuit

Diagram Courtesy of HYUNDAI MOTOR CO.
ECM: Electronic Controlled Mounting
ECM SPECIFICATIONS
SOLENOID
SYSTEM CONDITION VALVE RELAY VOLTAGE
~ 810RPM ON (idle) 9V ~
Semi-active engine mount or After ignition Hold the previous
Electronic Controlled Mounting switch is ON 810~910RPM state. 2~9V
(ECM) 910PRM ~ OFF (driving)
~ 2V
Ignition switch is OFF OFF
TROUBLESHOOTING
Fig. 10: Troubleshooting Flow Chart (1 Of 3)


COMPONENTS
Fig. 13: Identifying Engine Block Components And Torque Specifications (1 Of 2)

Fig. 14: Identifying Engine Block Components And Torque Specifications (2 Of 2)

REMOVAL
1. Remove the drive plate (A).
Fig. 15: Locating Drive Plate

2. Remove the rear plate (A).
Fig. 16: Locating Rear Plate

3. Remove timing belt.

4. Remove intake manifold.
5. Remove exhaust manifold.
6. Remove generator from engine.(Refer to STEERING COLUMN AND SHAFT -- SANTA FE ).
7. Remove power steering pump from engine.(Refer to HEATING, VENTILATION & AIR
CONDITIONING -- SANTA FE ).
8. Remove cylinder head.
9. Remove A/C compressor from engine.(Refer to CHARGING SYSTEM (ENGINE ELECTRICAL

SYSTEM (G6EA-GSL 2.7)) -- SANTA FE ).
10. Remove water pump assembly.
DISASSEMBLY
1. Remove the power steering pump bracket (A) and the knock sensor (B).
Fig. 17: Locating Power Steering Pump Bracket And Knock

Sensor Courtesy of HYUNDAI MOTOR CO.
2. Remove the air conditioning compressor bracket (A).
Fig. 18: Locating Air Conditioning Compressor Bracket

3. Remove the lower oil pan (A).
Fig. 19: Locating Lower Oil Pan

4. Remove the oil screen (A).
Fig. 20: Locating Oil Screen

5. Remove the upper oil pan (A).
Fig. 21: Locating Upper Oil Pan

CAUTION: When removing the oil pan, use the SST (09215-3C000) not to
damage the contacting surface of the oil pan.
6. Check the connecting rod side clearance.

7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.
NOTE:
Keep the bearings the connecting rods and the caps together.
Arrange the piston and connecting rod assemblies in the correct
order.
9. Remove the oil pump case.

10. Remove the oil seal case (A).
Fig. 22: Locating Oil Seal Case

11. Check the crankshaft end play.

12. Remove the crankshaft bearing cap and check oil clearance.
Fig. 23: Identifying Crankshaft Bearing Cap

NOTE: Arrange the bearings and the bearing caps in order.
13. Lift the crankshaft (A) out of the block, being careful not to damage journals.
Fig. 24: Locating Crankshaft

14. Remove and arrange the main bearings and thrust bearings in the correct order.
Fig. 25: Locating Main Bearings

15. Remove the CKP sensor (A).
Fig. 26: Locating CKP Sensor

16. Check the free play between a piston and a piston pin. Try to move the piston back and forth on the piston
pin. If any movement is felt, replace the piston and the piston pin as a set.
17. Remove the piston rings.
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the 2 side rails and the oil ring by hand.
NOTE: Arrange the piston rings in the correct order only.
18. Disconnect the connecting rod from the piston. Using a press, remove the piston pin from the piston.
(Press-in load : 2451.7 ~ 12258.3N (250 ~ 1250kg, 551.2 ~ 2755.81lb)
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.
Specification
Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)
Limit : 0.4mm (0.0157in.)
Fig. 27: Checking Connecting Rod Side Clearance

If out-of-tolerance, install a new connecting rod.

If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
1. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
3. Remove the connecting rod cap and the lower bearing.
4. Clean the crankshaft pin journal and the bearing.
5. Place a plastigage across the crankshaft pin.
6. Reinstall the lower bearing and the connecting rod cap and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°
NOTE: Do not turn the crankshaft.
7. Remove the connecting rod cap again.

8. Measure the plastigage at its widest point.
Standard oil clearance
0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)
Fig. 28: Measuring Plastigage At Widest Point

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.
10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.
NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.
CONNECTING ROD MARK LOCATION
Fig. 29: Locating Connecting Rod Mark

DISCRIMINATION OF CONNECTING ROD
DISCRIMINATION OF CONNECTING ROD

CLASS MARK INSIDE DIAMETER
0 A 51.000 ~ 51.006 (2.0079 ~ 2.0081 in.)
1 B 51.006 ~ 51.012mm (2.0081 ~ 2.0083in.)
2 C 51.012 ~ 51.018mm (2.0083 ~ 2.0086in.)
CRANKSHAFT PIN MARK LOCATION
DISCRIMINATION OF CRANKSHAFT
Fig. 30: Identifying Crankshaft Pin Mark Location

CLASS MARK OUTSIDE DIAMETER OF PIN
I A 47.994 ~ 48.000mm (1.8895 ~ 1.8898in.)
II B 47.988 ~ 47.994mm (1.8893 ~ 1.8895in.)
III C 47.982 ~ 47.988mm (1.8891 ~ 1.8893in.)
PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)
Fig. 31: Locating Connecting Rod Bearing Mark

DISCRIMINATION OF CONNECTING ROD BEARING
DISCRIMINATION OF CONNECTING ROD BEARING

CLASS MARK THICKNESS OF BEARING
A BLUE 1.5000 ~ 1.503mm (0.0591 ~ 0.0592in.)
B BLACK 1.497 ~ 1.500mm (0.0589 ~ 0.0591 in.)
C - 1.494 ~ 1.497mm (0.0588 ~ 0.0589in.)
D GREEN 1.491 ~ 1.494mm (0.0587 ~ 0.0588in.)
E YELLOW 1.488 ~ 1.491mm (0.0586 ~ 0.0587in)
11. Select the proper connecting rod bearing from the table below.
CONNECTING ROD BEARING SPECIFICATIONS

CONNECTING ROD IDENTIFICATION
MARK
0 (A) 1 (B) 2 (C)
I (A) E (YELLOW) D (GREEN) C (-)
CRANKSHAFT IDENTIFICATION II (B) D (GREEN) C (-) B (BLAC
MARK III
C (-) B (BLACK) A (BLUE
(C)
3. Check the connecting rod.

1. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing
a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same
direction.
2. If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner
surface of the rod is damaged or rough, also replace it.
3. Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the
specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it.
Bending : 0.05mm/100mm (0.0020in./3.9370in.)
Torsion : 0.1mm/100mm (0.0039in./3.9370in.)
NOTE: When assembling the rod without a bearing, there should be no

difference.
4. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8 : 15.7Nm (1.6 kgf.m, 11.6lb-ft) + 90°
M10 : 29.4 Nm (3.0 kgf.m, 21.7lb-ft)+ 90°
NOTE: Tighten the bolts in order.
5. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil
clearance
0.004 ~ 0.022mm (0.0002 ~ 0.0009in.)
Fig. 32: Measuring Widest Part Of Plastigage

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.
7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.
NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.
CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.
Crankshaft bore mark location
Letters have been stamped on the block as a mark for the each size of the 4 main journal bores.
No.1 journal stamping mark starts from the front of the engine.
Use the size marks which are stamped on the block and the crankshaft for the journal bore
inner diameter and the journal outer diameter to choose the correct bearings.
Fig. 33: Identifying Crankshaft Bore Mark

DISCRIMINATION OF CYLINDER BLOCK
DISCRIMINATION OF CYLINDER BLOCK

CLASS MARK INSIDE DIAMETER
a A 66.000 ~ 66.006mm (2.5984 ~ 2.5987in.)
b B 66.006 ~ 66.012mm (2.5987 ~ 2.5989in.)
c C 66.012 ~ 66.018mm (2.5989 ~ 2.5991 in.)
CRANKSHAFT JOURNAL MARK LOCATION
Fig. 34: Identifying Crankshaft Journal Mark

CLASS MARK OUTSIDE DIAMETER OF JOURNAL
I A 61.994 ~ 62.000mm (2.4407 ~ 2.4409in.)
II B 61.988 ~ 61.994mm (2.4405 ~ 2.4407in.)
III C 61.982 ~ 61.988mm (2.4402 ~ 2.4405in.)
PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)
Fig. 35: Identifying Mark On Crankshaft Bearing

DISCRIMINATION OF CRANKSHAFT BEARING
DISCRIMINATION OF CRANKSHAFT BEARING

CLASS MARK THICKNESS OF BEARING
A BLUE 2.007 ~ 2.010mm (0.0790 ~ 0.0791 in.)
B BLACK 2.004 ~ 2.007mm (0.0789 ~ 0.0790in.)
C - 2.001 ~ 2.004mm (0.0788 ~ 0.0789in.) D GREEN 1.998 ~ 2.001mm (0.0787 ~
0.0788in.) E YELLOW 1.995 ~ 1.998mm (0.0785 ~ 0.0787in.)
SELECTION TABLE
SELECTION CHART
CRANKSHAFT BORE IDENTIFICATION
MARK
a (A) b (B) c (C)
I (A) E (YELLOW) D (GREEN) C (-)
CRANKSHAFT IDENTIFICATION II (B) D (GREEN) C (-) B (BLAC

MARK III
C (-) B (BLACK) A (BLUE
(C)
5. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with
a screwdriver.
Standard end play
0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
[Limit]
0.3mm (0.0118in.)
Fig. 36: Measuring Crankshaft End Play

If the end play is greater than the maximum, replace the center bearing.
Thrust bearing thickness
1.925 ~ 1.965mm (0.0758 ~ 0.0774in.)
6. Inspect the main journals and the pin journals of the crankshaft.
7. Using a micrometer, measure the outer diameter of each main journal and pin journal.
Main journal diameter: 61.982 ~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter : 47.982 ~ 48.000mm (1.8891 ~ 1.8898in.)
Fig. 37: Measuring Outer Diameter Of Main Journal And Pin

Journal Courtesy of HYUNDAI MOTOR CO.
CYLINDER BLOCK
1. Remove gasket materials.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard : 0.03mm (0.0012in.) or less
Fig. 38: Inspecting Top Surface Of Cylinder Block For

Flatness Courtesy of HYUNDAI MOTOR CO.
4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block or process the piston to be oversized.
5. Inspect the cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and
axial directions.
Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4146in.)
Fig. 39: Measuring Cylinder Bore Diameter

6. Check the cylinder bore size code (A) on the cylinder block.
Fig. 40: Identifying Cylinder Bore Size Code

CYLINDER BORE SIZE CODE SPECIFICATIONS

Class Size code Cylinder bore inner diameter
A A 86.70 ~ 86.71mm (3.4134 ~ 3.4138in.)
B B 86.71 ~ 86.72mm (3.4138 ~ 3.4142in.)
C C 86.72 ~ 86.73mm (3.4142 ~ 3.4146in.)
7. Check the piston size code (A) on the piston top face.
Fig. 41: Locating Piston Size Code On Piston Top

Face Courtesy of HYUNDAI MOTOR CO.
PISTON SIZE CODE SPECIFICATIONS

Class Size code Piston outer diameter
A A 86.67 ~ 86.68mm (3.4122 ~ 3.4126in.)
B B 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.)

C C 86.69 ~ 86.70mm (3.4130 ~ 3.4134in.)
8. Select the proper piston related to the cylinder bore class. Clearance : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in.)
CYLINDER BORING
1. The over size piston is chosen on the maximum inner diameter of the cylinder.
NOTE: The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.

3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 ~ 0.04mm (0.0008~0.0016in.)[clearance]
- 0.01mm (0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
CAUTION: Bore the cylinders in firing order to prevent the cylinders from be
twisted by high temperature.
5. Stop boring and start horning for the proper clearance.

6. Measure the clearance between a piston and a cylinder. Specification
0.02 ~ 0.04mm (0.0008 ~ 0.0016in.)
NOTE: Bore all the cylinders with the same over size.
PISTON AND RINGS
1. Clean pistons.
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 13.5 mm (0.5315 in) from the bottom of
the piston.
Standard diameter
86.67 ~ 86.70 (3.4122 ~ 3.4134in.)
Fig. 42: Measuring Piston Outside Diameter

3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance
0.02 ~ 0.04mm (0.0008 ~ 0.0016in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the ring groove.
Piston ring side clearance
Standard
No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031 in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
Fig. 43: Checking Piston Ring Side Clearance

If the clearance is greater than the maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler
gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the
cylinder bore diameter. If the bore is over the service limit, the cylinder block must be replaced or bored
Piston ring end
gap Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.30 ~ 0.45m (0.0118 ~ 0.0177in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
Fig. 44: Measuring Piston Ring End Gap

PISTON PINS
1. Measure the outer diameter of the piston pin.
Piston pin outer diameter
21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
Fig. 45: Measuring Outer Diameter Of Piston Pin

2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.011 ~ 0.018mm (0.0004 ~ 0.0007in.)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner
diameter.
Piston pin-to-connecting rod interference
-0.033 ~ -0.016mm (-0.0013 ~ -0.0006in.)
REASSEMBLY
NOTE:
Thoroughly clean all parts before reassembling.
Before installing the parts, apply fresh engine oil to all sliding and
rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. Assemble the piston and the connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark must face the timing belt side of the
engine.
Fig. 46: Locating Piston Front Mark

2. Install piston rings.

1. Install the oil ring spacer and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown.
Fig. 47: Identifying Piston Rings Gap Direction

3. Install the connecting rod bearings.

1. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B).
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
Fig. 48: Identifying Bearings And Connecting Rod

Cap Courtesy of HYUNDAI MOTOR CO.
CAUTION: When reassembling the connecting rods and the caps, ensure
the front marks on them.
4. Install the CKP sensor (A). Tightening torque
6.9 ~ 9.8Nm (0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft)
Fig. 49: Locating CKP Sensor

5. Install main bearings.
NOTE: Upper bearings have the oil grooves of the oil holes; Lower bearings do
not.
1. Aligning the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings
(A).
Fig. 50: Locating Main Bearings

2. Aligning the bearing claw with the claw groove of the main bearing cap, push in the 4 lower
bearings (B) on the bearing caps (A).
Fig. 51: Identifying Lower Bearings And Bearing

Caps Courtesy of HYUNDAI MOTOR CO.
6. Install thrust bearings.
Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil
grooves facing outward.
Fig. 52: Locating Thrust Bearings

7. Place crankshaft (A) on the cylinder block.
Fig. 53: Placing Crankshaft On Cylinder Block

8. Place main bearing caps on cylinder block.

9. Install main bearing cap bolts.
1. Install and uniformly tighten the bearing cap bolts, in two steps, in the sequence shown.
Tightening torque
M8 : 15.7Nm (1.6 kgf.m, 11.6lb-ft) + 90°
M10 : 29.4Nm (3.0 kgf.m, 21.7lb-ft)+ 90°
NOTE:
Use new main bearing cap bolt with engine oil applied.
If any of the bearing cap bolts are broken or deformed, replace
it.
Washers have their direction (Up/Down)
Assemble the bearing cap bridge on which its arrow mark faces
the engine front.
Before tightening, make the bearing caps be seated on the
block firmly.
Fig. 54: Identifying Main Bearing Cap Bolt In

Sequence Courtesy of HYUNDAI MOTOR CO.
NOTE: Use SST ( 09221-4A000 ), install main bearing cap bolts.
Fig. 55: Tightening Main Bearing Cap Bolts

2. Check that the crankshaft turns smoothly.

10. Check crankshaft end play.
11. Install the piston and connecting rod assemblies.
NOTE:
Before installing the pistons, apply a coat of engine oil to the ring
grooves and cylinder bores.
When installing the piston, ensure that the coat on the cylinder wall
is not damaged or scratched.
1. Install the ring compressor, check that the bearing is securely in place, then position the piston in the
cylinder, and tap it in using the wooden handle of a hammer.
2. Stop inserting the piston when the ring inserted in the cylinder and check the alignment of the
journal and the connecting rod.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb-ft) + 90°
NOTE:
Always use new connecting rod bolts.
Maintain downward force on the ring compressor to prevent the rings
from expanding before entering the cylinder bore.
Fig. 56: Inserting Piston In Cylinder Block

Use SST (09221-4A000), install connecting rod bearing cap bolts.
Fig. 57: Tightening Connecting Rod Bearing Cap

Bolts Courtesy of HYUNDAI MOTOR CO.
12. Install the rear oil seal case.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)
Fig. 58: Locating Rear Oil Seal Case

1. Clean the sealing surface face before assembling the two parts.
NOTE:
Remove harmful foreign materials on the sealing face before
applying sealant
Apply sealant to the inner threads of the bolt holes.
2. Assembling rear oil seal case, the liquid sealant TB1217H should be applied to the rear oil seal case.
The part must be assembled within 5 minutes after sealant was applied.
Fig. 59: Applying Sealant To Inner Threads Of Bolt

Holes Courtesy of HYUNDAI MOTOR CO.
13. Using SST (09231-33000), install rear oil seal after applying engine oil on the rip of the oil seal.
14. Install the oil pump case.
15. Install upper oil pan.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. The
part must be assembled within 5 minutes after the sealant was applied.
Fig. 60: Applying Liquid Sealant On Upper Oil Pan

NOTE:
Clean the sealing face before assembling two parts.
Remove harmful foreign materials on the sealing face
before applying sealant.
When applying sealant gasket, sealant must not protrude
into the inside of oil pan.
To prevent leakage of oil, apply sealant gasket to the
inner threads of the bolt holes.
3. Install upper oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
Bolts 1 ~ 15 : 18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Bolts 16,17 : 4.9 ~ 6.9Nm (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
Fig. 61: Tightening Bolts In Sequence

16. Install the oil screen (A).
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

17. Install the lower oil pan.

2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on lower oil pan. The
NOTE:
Clean the sealing face before assembling two parts.
Remove harmful foreign materials on the sealing face
before applying sealant.
When applying sealant gasket, sealant must not protrude
into the inside of oil pan.
3. Install lower oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

18. Install the air conditioning compressor bracket (A). (Refer to HEATING, VENTILATION & AIR
CONDITIONING -- SANTA FE )
Fig. 64: Locating Air Conditioning Compressor Bracket

19. Install the power steering pump bracket (A) and the knock sensor (B).
Tightening torque
18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Fig. 65: Locating Power Steering Pump Bracket And Knock

Sensor Courtesy of HYUNDAI MOTOR CO.
CAUTION:
On Bank 1, the black knock sensor connector should be
installed and on Bank 2, the gray one should.
INSTALLATION
1. Install the water pump.

2. Install the air conditioning compressor.(Refer to HEATING, VENTILATION & AIR
3. Install the cylinder head.
4. Install the power steering pump.(Refer to STEERING COLUMN AND SHAFT -- SANTA FE ).
5. Install the generator.
6. Install the intake manifold.
7. Install the exhaust manifold.
9. Install the rear plate (A).
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Fig. 66: Locating Rear Plate

10. Install the drive plate (A).
Tightening torque
71.6 ~ 75.5Nm (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)
Fig. 67: Locating Drive Plate

COOLING SYSTEM
COMPONENTS
Fig. 68: Identifying Cooling System Components (1 Of 2)

Fig. 69: Identifying Cooling System Components (2 Of 2)

ENGINE COOLANT REFILLING AND BLEEDING
WARNING: Never remove the radiator cap when the engine is hot. Serious scalding
could be caused by hot fluid under high pressure escaping from the
radiator.
CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to
let coolant spill on the electrical parts or the paint. If any coolant spills,
rinse it off immediately.
1. Make sure the engine and radiator are cool to the touch.
2. Open the radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and clean the reservoir tank.
6. Fill water slowly through the radiator cap. Push the upper/lower hoses of the radiator so as to bleed air
easily.
7. Warm the engine until the cooling fan operates 2~3 times. Accelerate the engine 2~3 times without load.
8. Wait until the engine is cold.

9. Repeat the steps 1~8 until the water drained is clean.
10. Fill fluid mixture with coolant and water (4 : 6) slowly through the radiator cap. Push the upper/lower
hoses of the radiator so as to bleed air easily.
11. Start the engine and run so coolant circulates. When the cooling fan operates and coolant circulates, refill
coolant through the radiator cap.
12. Repeat 11 until the cooling fan cycles 3 ~ 5 times and bleed air sufficiently out of the cooling system.
13. Install the radiator cap and fill the reservoir tank to the "MAX" (or "F") line with coolant.
14. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
15. Stop the engine and wait until coolant gets cool.
16. Repeat 10 to 15 until the coolant level doesn't fall any more, bleeding air out of the cooling system.
NOTE: Check the coolant level again in the reservoir tank for 2 ~ 3 days after
replacing coolant.
CAP TESTING
1. Remove the radiator cap, wet its seal with engine coolant, and install it to a pressure tester.
Fig. 70: Identifying Radiator Cap Onto Pressure Tester

2
2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm , 14 ~ 19psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.
REMOVAL
WATER PUMP
1. Drain the engine coolant.
WARNING: System is under high pressure when the engine is hot. To avoid
danger of releasing scalding engine coolant, remove the cap
only when the engine is cool.
2. Remove drive belt (A).
Fig. 71: Locating Drive Belt


4. Remove the water pump (A) and gasket (B).
Fig. 72: Locating Water Pump And Gasket

WATER TEMPERATURE CONTROL ASSEMBLY
1. Drain the engine coolant.

2. Remove the air cleaner assembly.
3. Disconnect the radiator upper and lower hose (A, B).
Fig. 73: Locating Radiator Upper And Lower Hose

4. Disconnect the ECT (Engine Coolant Temperature) sensor connector.

5. Remove the coolant hose related to the heater hoses and the ECT (Engine Coolant Temperature) system.
6. Remove wiring protector.
7. Remove water temperature control assembly (A) and the gaskets (B).
Fig. 74: Locating Water Temperature Control Assembly And

Gaskets Courtesy of HYUNDAI MOTOR CO.
8. Remove the water pipe (A).
Fig. 75: Locating Water Pipe

THERMOSTAT
NOTE: Removal of the thermostat would have an adverse effect, causing a lowering of
cooling efficiency. Do not remove the thermostat, even if the engine tends
to overheat.
1. Drain engine coolant so its level is below thermostat.

2. Remove the coolant inlet pitting (A) and the thermostat (B).
Fig. 76: Locating Coolant Inlet Pitting And

Thermostat Courtesy of HYUNDAI MOTOR CO.
RADIATOR
1. Drain the engine coolant. Remove the radiator cap to speed coolant draining.
2. Remove the air duct.
3. Remove the upper radiator hose (A) and lower radiator hose.
Fig. 77: Locating Upper Radiator Hose

4. Disconnect the radiator fan connector.(A, B)
LH
Fig. 78: Disconnecting Radiator Fan Connector - LH

RH
Fig. 79: Disconnecting Radiator Fan Connector - RH

5. Remove the radiator grill upper cover.(A)
Fig. 80: Locating Radiator Grill Upper Cover

6. Remove the head lamp washer nozzle cover and front bumper.(Refer to EXTERIOR -- SANTA FE )
7. Remove the radiator cap hose.(A)
Fig. 81: Locating Radiator Cap Hose

8. First, remove the cooling fan.(First, separate LH side)
NOTE: Remove the bracket bolt of radiator lower hose.
9. Remove the radiator bracket bolt of the radiator upper side (A).
LH
Fig. 82: Locating Radiator Bracket Bolt - LH

RH
Fig. 83: Locating Radiator Bracket Bolt - RH

10. Remove the radiator assembly from the engine.
INSPECTION
WATER PUMP
1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump
assembly if necessary.
3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump
assembly.
NOTE: A small amount of "weeping" from the bleed hole is normal.
THERMOSTAT
1. Immerse the thermostat in water and gradually heat water.
Fig. 84: Checking Valve Opening Temperature

2. Check the valve opening temperature. Valve opening temperature : 82°C (177°F) Full opening temperature :
95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift: Min. 10mm (0.4in.) at 95°C (205°F) If the valve lift is not as specified, replace the thermostat.
INSTALLATION
WATER PUMP
1. Install the water pump (A) and a new gasket (B) with the bolts.
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
Fig. 85: Locating Water Pump And Gasket

NOTE: Clean the contacting face before assembling.

3. Install the engine support bracket Tightening torque : 6 ~ 7kgf.m
CAUTION: Over-torque can damage thread of cylinder block.
4. Install drive belt (A).

5. Fill with engine coolant.

6. Start engine and check for leaks.
7. Recheck engine coolant level.
WATER TEMPERATURE CONTROL ASSEMBLY
1. Install the water pipe (A).
Tightening torque
16.7 ~ 19.6Nm (1.7 ~ 2.0kgf.m, 12.3 ~ 14.5lb-ft)
Fig. 87: Locating Water Pipe

2. Install the water temperature control assembly (A) with a new gasket (B).
Tightening torque
29.4 ~ 41.2Nm (3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft
Fig. 88: Locating Water Temperature Control Assembly And

Gaskets Courtesy of HYUNDAI MOTOR CO.
NOTE: Use new O-rings and wet them with water or coolant when reassembling.
3. Install the wiring protector.

4. Connect the heater hose and ECT hose.
5. Connect the ECT sensor connector.
6. Connect the radiator upper and the lower hose (A).

7. Install the air cleaner assembly.

THERMOSTAT
1. Place thermostat (B) in coolant inlet pitting (A). Install the thermostat with the jiggle valve upward.
Fig. 90: Locating Coolant Inlet Pitting And

Thermostat Courtesy of HYUNDAI MOTOR CO.
2. Install the coolant inlet pitting (A).
Tightening torque
16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft)

RADIATOR
1. Install the engine from radiator assembly.

2. Install the radiator bracket bolt.(A)
LH
Fig. 91: Locating Radiator Bracket Bolt - LH

RH
Fig. 92: Locating Radiator Bracket Bolt - RH

3. Install the air conditioner condenser. (refer to HEATING, VENTILATION & AIR CONDITIONING
4. Install the cooling fan.
5. Install the radiator cap hose.(A)
Fig. 93: Locating Radiator Cap Hose

6. Install the front bumper and head lamp washer nozzle cover.(Refer to EXTERIOR )
7. Install the radiator grill upper cover.(A)
Fig. 94: Locating Radiator Grill Upper Cover

8. Connect the radiator fan connector.(A, B)
LH
Fig. 95: Connecting Radiator Fan Connector - LH

RH
Fig. 96: Connecting Radiator Fan Connector - RH

9. Install the upper radiator hose.(A)
Fig. 97: Locating Upper Radiator Hose

10. Install the air duct.

11. Refill with engine coolant.
LUBRICATION SYSTEM
COMPONENTS
Fig. 98: Identifying Lubrication System Components

INSPECTION
1. Check engine oil quality.
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace oil.
2. Check the engine oil level.
After warning up the engine, make the engine stand still for five minutes or more. The oil level should
be between the 'L' and 'F' marks on the dipstick, then.
If low, check for leakage and add oil up to the "F" mark.
NOTE: Do not fill with engine oil above the "F" mark.
SELECTION OF ENGINE OIL
Recommended API classification : Above SJ or SL Recommended SAE viscosity grades : 5W-20
Fig. 99: Identifying Recommended SAE Viscosity

Number Courtesy of HYUNDAI MOTOR CO.
NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which:
Satisfy the requirement of the API classification.

Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API
service classification on the container should not be used.
REMOVAL
OIL PUMP CASE
1. Drain engine oil.

2. Remove the front right wheel and tire.
3. Remove the front right side cover.
4. Remove the front muffler.
5. Remove the generator.
7. Remove the oil filter bracket (A).
Fig. 100: Locating Oil Filter Bracket

8. Using SST (09215-3C000), remove the lower oil pan (A).
Fig. 101: Locating Lower Oil Pan
CAUTION: Be careful not to damage the contact surfaces of upper oil pan and
lower oil pan.
9. Remove the oil screen (A).

10. Remove the upper oil pan, using the SST (09215-3C000)(A).
Fig. 103: Identifying Upper Oil Pan And SST

CAUTION: Be careful not to damage the contact surfaces of upper oil pan and
lower oil pan.
11. Remove the oil pump case (A).
Fig. 104: Locating Oil Pump Case

12. After removing the plug (A), remove the relief spring (B) and the valve plunger (C).
Fig. 105: Locating Plug, Relief Spring And Velief

Plunger Courtesy of HYUNDAI MOTOR CO.
INSPECTION
RELIEF SPRING
1. Check the relief plunger.
Apply engine oil on the plunger and check that it moves smoothly in the hole. If it does not, replace
the plunger or the front case only in necessary cases.
2. Check the relief valve spring.
Check deformation or damage of the relief valve spring.
Specification
Free length : 43.8mm (1.7244in.)
Load : 36.3N (3.7kg, 8.21b)±3.9N (0.4kg, 0.9lb)/40.1mm (1.5787in.)
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity,
replace the oil pressure switch.
Fig. 106: Checking Continuity Between Terminal And Body With

Ohmmeter Courtesy of HYUNDAI MOTOR CO.
2. Check the continuity between the terminal and the body when its hole is pushed by a fine rod (A). If there
is continuity with pressed, replace the switch.
Fig. 107: Checking Continuity Between Terminal And

Body Courtesy of HYUNDAI MOTOR CO.
2
3. If there is no continuity when the pressure 49.3kpa (0.5kg/cm , 7.11psi) is applied through the oil hole,
the switch is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace the switch.
REPLACEMENT
OIL AND FILTER
CAUTION:
Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil contains potentially

harmful contaminants which may cause skin cancer.
Wear protective clothing and gloves in order to minimize the
length and frequency of contact of your skin to used oil. Wash
your skin thoroughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use gasoline,
thinners, or solvents.
In order to preserve environment, used oil or used oil filter must
be disposed only at designated disposal sites.
1. Park the car on a level ground. Start the engine and let it warm up.
2. Turn the engine off.

3. Drain engine oil.
1. Remove the oil filler cap.
2. After lifting the car, remove the oil drain plug (A) and drain oil into a container.
4. Replace the oil filter.
1. Remove the oil filter (B).
Fig. 108: Locating Oil Filter And Oil Drain Plug

2. Check the part number of a new oil filter is as the same as that of the old one.
3. Replace the oil filter.
4. Tighten it slightly until the o-ring of the filter cap contacting on its position.
5. Tighten it with the specified torque.
Tightening torque
16.7 ~ 24.5Nm (1.7 ~ 2.5kgf.m, 12.3 ~ 18.1lb-ft)
5. Refill with engine oil.

1. Install the oil drain plug with a new gasket.
Tightening torque
34.3 ~ 44.1 Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
2. Fill with fresh engine oil, after removing the engine oil level gauge.
Capacity
Total : 4.5L (4.76U.S.qts,3.96lmp.qts)
Oil pan : 4.2L (4.44U.S.qts,3.70lmp.qts)
Oil filter: 0.3L (0.32U.S.qts,0.26lmp.qts)
3. Install the oil filler cap and the oil level gauge.
6. Start the engine and ensure that no oil is leaking from the drain plug or the oil filter.
7. Recheck engine oil level.
INSTALLATION
OIL PUMP CASE
1. Assembly the relief spring (B) and the relief plunger (C) and tighten the plug (A).
Tightening torque
39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
Fig. 109: Locating Plug, Relief Spring And Velief Plunger
2. Install oil pump case.

2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan. The
Bead width : 2.5mm (0.0984in.)
Fig. 110: Applying Liquid Sealant On Oil Pan

CAUTION:
Make clean the sealing face before assembling two parts.
Remove harmful foreign materials on the sealing
face before applying sealant.
When applying sealant gasket, sealant must not
be protrude into the inside of oil pan.
After assembly, wait at least 30 minutes before filling
the engine with oil.
3. Install the oil pump case (A).
Tightening torque
18.6 ~ 23.5 (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Fig. 111: Locating Oil Pump Case

CAUTION: In the installation of the oil pump, always use a new o-ring (B).
3. Using the SST (09214-33000), install the oil pump case oil seal.
Fig. 112: Installing Oil Pump Case Oil Seal

4. Install the upper oil pan.


CAUTION:
3. Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
Bolts 1 ~ 15 : 18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Bolts 16,17 : 4.9 ~ 6.9Nm (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)

5. Install the oil screen.
Tightening torque
14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

NOTE: Always use a new gasket.
6. Install the lower oil pan.


CAUTION:
3. Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

7. Install the oil filter bracket (A).
Tightening torque
18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Fig. 118: Locating Oil Filter Bracket

CAUTION: Always use a new O-ring.
8. Install the timing belt, the generator and the front muffler.
9. Install the front right side cover and the wheel and tire.
INTAKE AND EXHAUST SYSTEM

COMPONENTS
Fig. 119: Identifying Intake And Exhaust System Components And Torque Specifications (1 Of
3) Courtesy of HYUNDAI MOTOR CO.
REMOVAL
INTAKE MANIFOLD ASSEMBLY

2. Remove the intake air hose and air cleaner assembly.
1. Disconnect the MAF connector (A).
2. Disconnect the breather hose (B) from air cleaner hose.
3. Remove the intake air hose and air cleaner assembly (C).
4. Disconnect the PCM connectors (D).
Fig. 122: Locating PCM Connectors And Intake Air Hose And Air Cleaner
Assembly Courtesy of HYUNDAI MOTOR CO.
Fig. 123: Locating PCM Connectors

3. Disconnect the engine wiring harness connectors.

1. Disconnect the No.1/No.2 knock sensor connectors (A,B)> the oil pressure switch connector (C),
the ignition coil harness (D) and the No.1 VIS (Variable Induction System) connector (E).
Fig. 124: Locating Engine Wiring Harness

Connectors Courtesy of HYUNDAI MOTOR CO.
2. Disconnect the bank 1 front/rear O2 sensor connectors (A).
Fig. 125: Disconnecting Bank 1 Front/Rear O2 Sensor

3. Disconnect the injection connectors (A,B,C), the ground lines (D), the condensor connector (E) and
the Ignition coil connectors (F).
Fig. 126: Locating Injection Connectors, Ground Lines, Condensor Connector And
Ignition Coil Connectors
4. Disconnect the injection harness connector (A), the No.2 VIS (Variable Induction System)
connector (B), the No. 1/No.2 OCV (Oil Control Valve) connectors (CD) and the OTS (Oil Temperature Sensor)
connector (E).
Fig. 127: Locating Injection Harness Connector, No.2 VIS (Variable Induction System)
Connector And No. 1/No.2 OCV (Oil Control Valve) Connectors (CD)
5. Disconnect the MAP (Manifold Absolute Pressure Sensor) connector (A), the ETC (Electronic Throttle
Control) connector (B) and the PCSV (Purge Control Solenoid Valve) connector (C).
Fig. 128: Locating MAP (Manifold Absolute Pressure Sensor) Connector AND ETC
(Electronic Throttle Control) Connector
Fig. 129: Locating PCSV (Purge Control Solenoid Valve)

Connector Courtesy of HYUNDAI MOTOR CO.
6. Disconnect the generator connector (A) and the air conditioning compressor connector (B).
Fig. 130: Locating Generator Connector And Air Conditioning Compressor

7. Disconnect the bank 2 CMP sensor connector (A) and the ECT (Engine Coolant Temperature)
sensor connector (B).
Fig. 131: Locating Bank 2 CMP Sensor Connector And ECT (Engine Coolant
Temperature) Sensor Connector
8. Disconnect the bank 2 front/rear O2 sensor connectors (A,B) and the CKP sensor connector (C).
Fig. 132: Locating Bank 2 Front/Rear O2 Sensor Connectors And CKP Sensor Connector
9. Disconnect the bank 1 CMP sensor connector (A).
Fig. 133: Locating Bank 1 CMP Sensor Connector

4. Remove the PCV (Plunge Control Valve) hose (A).
Fig. 134: Locating PCV (Plunge Control Valve) Hose

5. Remove the ETC (Electric Throttle Control) bracket (A) and the cooling hoses (B).
Fig. 135: Locating ETC (Electric Throttle Control) Bracket And Cooling Hoses
6. Disconnect the brake vacuum hose (A).
Fig. 136: Locating Brake Vacuum Hose

7. Remove the surge tank mounting bracket (A).
Fig. 137: Locating Surge Tank Mounting Bracket

8. Remove the surge tank (A).
Fig. 138: Locating Surge Tank

9. Remove the delivery pipe assembly (A).
Fig. 139: Locating Delivery Pipe Assembly

10. Remove the intake manifold assembly (A).
Fig. 140: Locating Intake Manifold Assembly

EXHAUST MANIFOLD ASSEMBLY
1. Remove the under cover.

2. Remove the front muffler (A).
Fig. 141: Locating Front Muffler

3. Disconnect the oxygen sensor connectors (A).
Fig. 142: Locating Oxygen Sensor Connectors (1 Of 2)

Fig. 143: Locating Oxygen Sensor Connectors (2 Of 2)

4. Remove the oil level gauge.

5. Remove the heat protector (A).
Fig. 144: Locating Heat Protector

6. Remove the exhaust manifold assembly (A).
INSTALLATION
INTAKE MANIFOLD ASSEMBLY
1. Install the intake manifold assembly with a new gasket to a cylinder head assembly. Tighten the bolts in
two steps.
Tightening torque
Step 1 (a~h): 3.9~5.9Nm (0.4~0.6kgf.m, 2.9~4.3lb-ft)
Step 2 (1~8): 18.6~23.5Nm (1.9~2.4kgf.m, 13.7~17.4lb-ft)

CAUTION: When installing the gasket on the cylinder head, check the
identification marks (LH/RH) not to be installed wrong.
2. Install the delivery pipe.

3. Connect the LH injector connector.
4. Install the surge tank.
Tightening torque
18.6~23.5Nm (1.9~2.4kgf.m, 13.7~17.4lb-ft)
5. Install the surge tank mounting bracket.
Tightening torque
18.6~23.5Nm (1.9~2.4kgf.m, 13.7~17.4lb-ft)
6. Install the ETC (Electronic Throttle Control) system fixing bracket.

7. Connect the hoses and connectors.
8. Install the air cleaner assembly.
9. Install the engine cover.
EXHAUST MANIFOLD ASSEMBLY
1. Install the exhaust manifold assembly with a new gasket.
Tightening torque
29.4~34.3Nm (3.0~3.5kgf.m, 21.7~25.3lb-ft)
2. Install the heat protector.
Tightening torque
16.7~21.6Nm (1.7~2.2kgf.m, 12.3~15.9lb-ft)
3. Install the front muffler assembly.
Tightening torque
39.2~58.8Nm (4.0~6.0kgf.m, 28.9~43.4lb-ft)
4. Connect the oxygen sensor connector.

5. Install the radiator assembly. (refer to RADIATOR
6. Install the under cover.
CYLINDER HEAD ASSEMBLY

COMPONENTS
Fig. 146: Identifying Cylinder Head Assembly Components And Torque Specifications (1 Of
Fig. 147: Identifying Cylinder Head Assembly Components And Torque Specifications (2 Of
REMOVAL
CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.

To avoid damage, unplug the wiring connectors carefully
while holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the air duct and the battery (A) after disconnecting the terminals (B) from the battery.
Fig. 148: Locating Air Duct And Battery And

Terminals Courtesy of HYUNDAI MOTOR CO.


4. Remove the upper radiator hose (A) and lower radiator hose (B).

5. Remove the fuel inlet hose (A) from the delivery pipe.
Fig. 152: Locating Fuel Inlet Hose


1. Disconnect the No.1/No.2 knock sensor connectors (A,B), the oil pressure switch connector (C), the
ignition coil harness (D) and the No.1 VIS (Variable Induction System) connector (E).

Fig. 154: Locating Front/Rear O2 Sensor

connector (B), the No. 1/No.2 OCV (Oil Control Valve) connectors (C,D) and the OTS (Oil Temperature
Sensor) connector (E).
Fig. 156: Locating Injection Harness Connector, No.2 VIS (Variable Induction
System) Connector And No. 1/No.2 OCV (Oil Control Valve) Connectors
Fig. 157: Locating MAP (Manifold Absolute Pressure Sensor) Connector And ETC


7. Disconnect the bank 2 CMP sensor connector (A) and the ECT (Engine Coolant Temperature)
sensor connector (B).

7. Remove the PCV (Pulge Control Valve) hose (A).
Fig. 163: Locating PCV (Pulge Control Valve) Hose


9. Remove the heater hoses.

10. Remove the drive belt (A).

11. Remove the power steering pump.(Refer to STEERING COLUMN AND SHAFT -- SANTA FE ).
12. Remove the exhaust manifold assembly.(Refer to 'INTAKE AND EXHAUST SYSTEM').
13. Remove the intake manifold assembly.(Refer to 'INTAKE AND EXHAUST SYSTEM').
14. Remove the timing belt.(Refer to 'TIMING SYSTEM').
15. Remove the ignition coils.
16. Remove the water temp, control assembly.
17. Remove the cylinder head cover (A).
Fig. 166: Locating Cylinder Head Cover

18. Remove the camshaft bearing cap (A).
Fig. 167: Locating Camshaft Bearing Cap

19. Remove the timing chain tensioner (A).
Fig. 168: Locating Timing Chain Tensioner

20. Remove the camshaft.

21. Remove the bank 1 timing belt rear cover (A).
Fig. 169: Locating Bank 1 Timing Belt Rear Cover

22. Remove the bank 2 timing belt rear cover (A).

23. Remove the CKP sensor connector bracket (A).
Fig. 171: Locating CKP Sensor Connector Bracket

24. Remove the cylinder head assembly.

1. Remove the bolts in 2-3 steps as following orders.
Fig. 172: Removing Bolts In Sequence

CAUTION: If the bolts are not removed as the order, the deformation of the
head assembly can be occurred.
2. Put the cylinder head assembly on a wooden block after removal from the cylinder block.
CAUTION: Ensure that the surface between the cylinder head and the block
is not damaged.
DISASSEMBLY
NOTE: Identify MLA (Mechanical Lash Adjuster), valves and valve springs as they are
removed so that each item can be reinstalled in its original position.
1. Remove MLA (Mechanical Lash Adjuster)s (A).
Fig. 173: Locating MLA (Mechanical Lash Adjuster)

2. Remove valves.
1. Using SST (09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.
Fig. 174: Compressing Valve Spring

2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Using SST (09222-29000), remove the valve stem seal.
Fig. 175: Removing Valve Stem Seal Using SST(09222-29000)

NOTE: Do not reuse the removed valve stem seals.
3. Remove OCV (Oil Control Valve)(A).
Fig. 176: Locating OCV (Oil Control Valve)

INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and
the manifolds for warpage.
Flatness of cylinder head gasket surface
Flatness of manifold gasket surface
Fig. 177: Measuring Surface Contacting Cylinder Block And

Manifolds Courtesy of HYUNDAI MOTOR CO.
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.

1. Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide inside diameter
Intake / Exhaust : 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.)
Fig. 178: Measuring Inside Diameter Of Valve Guide

2. Using a micrometer, measure the outer diameter of the valve stem.
Valve stem outer diameter
Intake : 5.965 ~ 5.980mm (0.2348 ~ 0.2354in.)
Exhaust: 5.950 ~ 5.565mm (0.2343 ~ 0.2348in.)
Fig. 179: Measuring Diameter Of Valve Stem

3. Calculate the clearance between the valve guides and the stems by difference between the valve
stem measured diameter and the valve guide measured inside diameter.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.050mm (0.0008 ~ 0.0020in.)
Exhaust: 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)
[Limit]
Intake : 0.10mm (0.0039in.) or less
Exhaust: 0.13mm (0.0051 in.) or less
2. Inspect valves.
1. Check the valve face angle.
2. Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
3. Check the valve head margin thickness.
If the margin thickness is less than the specification, replace the valve.
Specification
Intake : 1.0mm (0.0394in.)
Exhaust: 1.3mm (0.0512.)
Fig. 180: Identifying Valve Head Margin Thickness

4. Check the valve length.
Length
Intake: 110.1mm (4.3346in)
Exhaust: 111.1mm (4.3740in)
5. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
1. Check the valve seat for evidence of overheating or improper contact with the valve face. If the
valve seat is worn, replace cylinder head.
2. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace
the valve guide first.
3. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should
be within specifications and centered on the valve face.
4. Inspect valve springs.
1. Using a steel square, measure the out-of-square of the valve spring.
2. Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 46.8mm (1.8425in.)
Out-of-square : 1.5° or less
Fig. 181: Measuring Free Length Of Valve Spring

MLA (MECHANICAL LASH ADJUSTER)
1. Inspect MLA.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust : 29.964 ~ 29.980mm (1.1797 ~ 1.1803in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust : 30.000 ~ 30.025mm (1.1811 ~ 1.182in.)
3. Calculate the clearance by subtracting MLA outside diameter measurement from tappet bore inside
diameter measurement.
MLA to tappet bore
clearance [Standard]
Intake/Exhaust: 0.020 ~ 0.061 mm (0.0008 ~
0.0024in.) [Limit]
Intake/Exhaust: 0.07mm (0.0027in.) or less
CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.5mm (1.7520in.)
Exhaust : 44.5mm (1.7520in.)
Fig. 182: Measuring Cam Lobe Height

If the cam lobe height is less than standard, replace the camshaft.
2. Check the cam lobe surface for wear or damage. If necessary, replace it.
3. Inspect camshaft journal clearance.
1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journals.
Fig. 183: Laying Strip Of Plastigage Across Each Of Camshaft

Journal Courtesy of HYUNDAI MOTOR CO.
4. Install the bearing caps with the tightening torque.
CAUTION: Do not turn the camshaft.
5. Remove the bearing caps.

6. Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake : 0.030 ~ 0.057mm (0.0012 ~ 0.0022in.)
Exhaust: 0.030 ~ 0.057mm (0.0012 ~ 0.0022in.)
Fig. 184: Measuring Plastigage Widest Point

If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace
the cylinder head.
7. Completely remove the plastigage.

8. Remove the camshafts.
4. Inspect camshaft end play.
1. Install the camshafts.
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value]: 0.1 ~ 0.2mm (0.0039 ~ 0.0079in.)
Fig. 185: Checking Camshaft End Play

If the end play is greater than the maximum, replace the camshaft. If necessary, replace the
cylinder head.
3. Remove the camshafts.
CVVT ASSEMBLY
1. Inspect CVVT assembly.

1. Fix the CVVT assembly with a vice. Ensure that the cam lobe and journal is not damaged.
2. Check that the CVVT assembly will not turn. It should not be turned.
3. Apply vinyl tape to the retard hole except the one (A) indicated by the arrow in the illustration.
Fig. 186: Locating Retard Hole

2
4. Wind tape around the tip of the air gun and apply air of approx. 150kpa (1.5kgf/cm , 21psi) to the
port of the camshaft.
(Perform this in order to release the lock pin for the maximum delay angle locking.)
NOTE: When the oil splashes, wipe it off with a shop rag.
5. After the lock pin released, the CVVT assembly can turned in advanced direction. If the air applied
is leaked much, the lock pin can not be released.
6. Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn
back and forth and check the movable range and that there is no resistance to movement.
Standard: Movable smoothly in the range about 60°
7. Turn the CVVT assembly with your hand in retard direction and lock it at the maximum delay angle
position.
Fig. 187: Turning CVVT Assembly

REPLACEMENT
VALVE GUIDE
1. Using the SST (09221-3F100A), remove the valve guide from the downside of the cylinder head
assembly.
Fig. 188: Locating Valve Guide

2. Reprocess the valve guide hole for the oversized valve guide newly installed.
3. Using the SST (09221-3F100A/B), insert the valve guide in the upside of the cylinder head assembly. Be
aware of the difference in length between the intake and the exhaust valve guides.
Specification
Intake valve guide: 45.8 ~ 46.2mm (1.8031 ~ 1.8189in.)
Exhaust valve guide: 46.8 ~ 47.2mm (1.8425 ~ 1.8583in.)
Fig. 189: Inserting Valve Guide In Upside Of Cylinder Head

4. After installing the valve guides, insert new valves and check the clearance between the valve stems and
the valve guides.
5. After replacing the valve guides, check if they are properly installed with the valve seats. Reprocess valve
seats if necessary.
REASSEMBLY
NOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace oil seals with new ones.
1. Install valves.
1. Using SST (09222-22001), push in a new valve stem seal with applying engine oil.
Fig. 190: Pushing Valve Stem Seal

NOTE:
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage

past the valve guides.
Reassemble the valve stem seals
2. After applying engine oil on the outer surface of each valve stem, insert the valve in the valve guide.
Install the valve, valve spring and spring retainer.
NOTE: When installing valve springs, the side coated with enamel should
face toward the valve spring retainer
3. Using the SST (09222 - 3K000, 09222-3C300), compress the springs and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.
Fig. 191: Compressing Valve Spring

4. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.
2. Install MLAs with engine oil applied on its surface. Check that the MLA rotates smoothly by hand.
Fig. 192: Locating MLA (Mechanical Lash Adjuster)

NOTE: MLA should be reinstalled in its original position.
3. Install OCV (Oil Control Valve)(A).
Tightening torque
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Fig. 193: Locating OCV (Oil Control Valve)

NOTE:
To install OCV with gray colored connector into RH bank.
To install OCV with black colored connector into LH bank.
CAUTION:
Do not reuse the OCV when
dropped. Keep clean the OCV.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move
the engine while holding the OCV yoke.
If there is dust on the filter (B) of the OCV, clean it all.
INSTALLATION
NOTE:
Thoroughly clean all parts to be assembled.
Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend
it. Rotate the crankshaft to set the No. 1 cylinder piston at TDC.
1. After putting the cylinder head gasket on the cylinder block, install the cylinder head.
Fig. 194: Identifying Cylinder Head Gasket Mark

CAUTION: Ensure the LH/RH classification of the cylinder head gasket when
installing.
2. Tighten the cylinder head bolts with the plain washers in several steps as following order.
NOTE:
In assembling washers, the marked surface should face upward.
In installing the cylinder head bolts, apply engine oil on the thread of
the bolts and the surface of the washers.
Tightening torque
24.5Nm (2.5kgf.m, 18.1lb-ft) + 60° + 45°
NOTE: Using the SST (09221-4A000), tighten the bolts which need to be tightened
with the angular tightening method.
Fig. 196: Tightening Bolts

3. Install the CVVT assembly and camshaft chain sprocket with the dowel pin in the CVVT installed to the
intake camshaft. Ensure that the pin will not be installed in the hole for oil feeding.
Tightening torque
66.7~78.5Nm (6.8~8.0kgf.m, 49.2~57.9lb-ft)
NOTE: After tightening the CVVT bolts, rotate the CVVT assembly housing
counterclockwise by hand to seat the lock pin in the CVVT assembly in
good position.
CAUTION: Fix the hexagonal part of the camshaft in a vice when tightening the
CVVT bolts. Do not fix the CVVT housing or sprocket in a vice.
4. Install the camshaft in the cylinder head assembly.

1. Align the timing mark of the camshaft timing chain.
LH CAMSHAFT CHAIN TIMING MARK
Fig. 197: Identifying LH Camshaft Chain Timing

Mark Courtesy of HYUNDAI MOTOR CO.
RH CAMSHAFT CHAIN TIMING MARK
Fig. 198: Identifying RH Camshaft Chain Timing

Mark Courtesy of HYUNDAI MOTOR CO.
CAUTION: Both timing marks should face upward in re-assembly.
5. Install the timing chain tensioner.

1. Insert the set pin by pressing the timing chain tensioner.
2. Install the chain tensioner (A) in the cylinder head assembly.
Fig. 199: Locating Chain Tensioner

6. Install the camshaft bearing caps.
Tightening torque
Bearing cap bolt (A: 6x38) - 10.8~12.7Nm (1.1~1.3kgf.m, 8.0~9.4lb-ft)
Bearing cap bolt (B: 8x38) - 20.6~22.5Nm (2.1~2.6kgf.m, 15.2~18.8lb-ft)
Fig. 200: Identifying Camshaft Bearing Caps

NOTE: When installing the bearing caps, check the marks on them as shown
below and install them in its proper position.
Fig. 201: Locating Bearing Caps Mark

A(LH/RH HEAD): L (LH), R (RH)
B(Intake/Exhaust): l (Intake), E (Exhaust)
C(Cap no.): 1,2,3
CAUTION: When installing the bearing caps, turn the crankshaft to place a
piston in the middle of the block because Interference between
valves and pistons can occur.
7. Using the SST (09214-21000), install the camshaft oil seal.
Fig. 202: Installing Camshaft Oil Seal

NOTE:
Before installing, apply engine oil.
The camshaft cap surface should adhere to the cylinder
head assembly.
Do not press an eccentric load.
8. Install the CKP sensor connector bracket (A).
Fig. 203: Locating CKP Sensor Connector Bracket

9. Install the bank 2 timing belt rear cover (A).

10. Install the bank 1 timing belt rear cover (A).

NOTE: The length of the bolt B is longer than that of the bolt C.
11. Install the timing belt.(Refer to 'TIMING SYSTEM').

12. Check and adjust the valve clearance.
13. Install the cylinder head cover.
1. Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head
cover.
2. Assemble the cylinder head cover in five minutes after applying liquid gasket (LOCTITE 5900) on
the camshaft cap and packing part.
Fig. 206: Identifying Cylinder Head Cover

3. Tighten the cylinder head cover bolts as following order (A).
Tightening torque
7.8~9.8Nm (0.8~1.0kgf.m, 5.8~7.2lb-ft)
Fig. 207: Tightening Cylinder Head Cover Bolts In

Sequence Courtesy of HYUNDAI MOTOR CO.
NOTE:
Do not start engine for thirty minutes after assembling the
cylinder head cover.
Do not reuse the cylinder head cover gasket.
14. Install the water temp, control assembly.

15. Install the engine support bracket.
NOTE: Over torque can damage thread of cylinder block.
16. Install the intake manifold assembly.

17. Install the exhaust manifold assembly.
18. Install the power steering pump.(Refer to STEERING COLUMN AND SHAFT -- SANTA FE ).
19. Install the drive belt (A).

20. Install the heater hose.

21. Connect the brake vacuum hose (A).

22. Install the PCV (Pulge Control Valve) hose (A).
Fig. 210: Locating PCV (Pulge Control Valve) Hose

23. Connect the engine wiring harness connectors.

1. Connect the bank 1 CMP sensor connector (A).

2. Connect the bank 2 front/rear O2 sensor connectors (A,B) and the CKP sensor connector (C).
3. Connect the bank 2 CMP sensor connector (A) and the WTS (Water Temperature Sensor) connector
(B).
4. Connect the generator connector (A) and the air conditioning compressor connector (B).

5. Connect the MAP (Manifold Absolute Pressure Sensor) connector (A), the ETC (Electronic Throttle

6. Connect the injection harness connector (A), the No.2 VIS (Variable Induction System) connector
(B), the No. 1/No.2 OCV (Oil Control Valve) connectors (C, D) and the OTS (Oil Temperature Sensor)
connector (E).
7. Connect the injection connectors (A,B,C), the ground lines (D), the condensor connector (E) and the
Ignition coil connectors (F).
8. Connect the bank 1 front/rear O2 sensor connectors (A).

9. Connect the No.1/No.2 knock sensor connectors (A,B), the oil pressure switch connector (C), the

24. Install the fuel inlet hose (A) from the delivery pipe.

25. Install the upper radiator hose (A) and lower radiator hose (B).

26. Install the intake air hose and air cleaner assembly.
1. Connect the PCM connectors (D).

2. Install the intake air hose and air cleaner assembly (C).
3. Connect the breather hose (B) from air cleaner hose.
4. Connect the MAF connector (A).
28. Refill engine coolant.
TIMING SYSTEM
TIMING BELT
COMPONENTS
Fig. 225: Identifying Timing System Components And Torque

Specifications Courtesy of HYUNDAI MOTOR CO.
REMOVAL

2. Remove the front right wheel and tire.
3. Remove the right side cover.
4. Remove the drive belt (A), the idler (B) and the tensioner (C).
Fig. 226: Locating Drive Belt, Idler And Tensioner

NOTE: In removing the drive belt, fix a tool in the auto tensioner pulley bolt and
turn the bolt counter clockwise.
5. Remove the timing belt upper cover (A).
Fig. 227: Locating Timing Belt Upper Cover

6. Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft
pulley clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head
cover at the moment. (No.1 cylinder piston at TDC)
Fig. 228: Identifying Timing Mark

7. Remove the engine mounting bracket.

1. Sustain the engine oil pan with a jack.
CAUTION: Put a wooden or rubber block between the jack and the engine
oil pan.
2. Remove the engine mounting bracket (A).
Fig. 229: Locating Engine Mounting Bracket

8. Remove the crankshaft damper pulley (A).
Fig. 230: Locating Crankshaft Damper Pulley

9. Remove the timing belt lower cover (A).
Fig. 231: Locating Timing Belt Lower Cover

10. Remove the engine support bracket (A).
Fig. 232: Locating Engine Support Bracket

NOTE: After the removal, engine coolant can be drained a little from that point (B)
which is a matter of no importance.
11. Remove the timing belt auto tensioner (A).
Fig. 233: Locating Timing Belt Auto Tensioner

12. Remove the timing belt (A).
Fig. 234: Locating Timing Belt

NOTE: Make a direction mark of revolution on the timing belt for re-use.
13. Remove the tensioner arm assembly (A) and the idler (B).
Fig. 235: Locating Tensioner Arm Assembly And Idler

14. Remove the crankshaft sprocket.
INSPECTION
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket and crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear,
cracks, or damage. Replace as necessary.
2. Inspect the tensioner and the idler for easy and smooth rotation and check for play or noise. Replace as
necessary.
Fig. 236: Identifying Tensioner And Idler

3. Replace the tensioner and the idler if grease is leaked from bearings.
TIMING BELT
1. Check the belt for oil or dust deposits. Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following
flaws are evident, replace the belt.
NOTE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water
and steam.
3. Inspect the idler for easy and smooth rotation and check for play or noise.
INSTALLATION
1. Install the crankshaft sprocket.

2. Install the tensioner arm assembly (A) and the idler (B).
Tightening torque
Tensioner arm bolt : 34.3 ~ 53.9Nm (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)
Idler pulley bolt : 49.0 ~ 58.8Nm (5.0 ~ 6.0kgf.m, 36.2 ~ 43.4lb-ft)
Fig. 237: Locating Tensioner Arm Assembly And Idler

3. Install the timing belt auto tensioner.

1. Fixing the tensioner with a vice and compressing the rod, insert a set-pin.
Fig. 238: Compressing Rod

NOTE:
Handle the auto tensioner in the vertical position.
If it is treated by laying, tilting or turning over, stand it vertically
for about five minutes in order for air to move upward.
Do not pull the pin out before its installation to the engine
assembly because pulling the pin can cause noise of timing
system by making air go in the high pressure chamber.
CAUTION:
When pressing the rod, use a vertical vice certainly.
There is a high possibility for air to get in the high
pressure chamber, when using a horizontal vice.
Do not apply more load than 400N on the rod.
Do not press the rod until its position is below 2.5mm from
the body surface.
The projection of the rod is secured more than 2.5mm.
NOTE:
Repairing orders when disassembling the auto tensioner and
reassembling it to the engine, or pulling the pin out before its
installation;
1. Stand it vertically for about five minutes.
2. Press the rod with the force, 150-200N.
3. If the rod has a stiffness, press it slowly and insert the pin
into the set hole.
4. If not (the tensioner is in 'sponge' state), press the rod
slowly from its maximum projection to 2.9mm position (the meeting point with the rod and the
hole of the body) two or three times.
Afterwards, if stiffness is sensed, insert the pin into

the hole. However, if not, scrap the tensioner.
2. Install the auto tensioner (A) to the front case with the set-pin inserted.
Tightening torque
19.6 ~ 26.5Nm (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Fig. 239: Locating Auto Tensioner
4. Ensure the tinning marks on the camshaft and the crankshaft sprockets.
Fig. 240: Identifying Timing Marks

Crankshaft sprocket (A) --> Idler (B) --> Bank 2 exhaust camsprocket (C) --> Water pump pulley (D)
--> Bank 1 exhaust camsprocket (E) --> Tensioner pulley (F).
Fig. 241: Identifying Timing Belt

6. Remove the auto tensioner set-pin.

7. Check the tension of the timing belt.
1. Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at TDC. After
5minutes, measure the length of the projected rod.
Specification
5 ~ 7mm (0.1969 ~ 0.2756in.)
Fig. 242: Identifying Length Of Projected Rod

2. Ensure the locations of the timing marks for each sprocket.

8. Install the engine support bracket (A).
Tightening torque
58.8 ~ 68.6Nm (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
Fig. 243: Locating Engine Support Bracket

CAUTION: Over torque can damage thread of cylinder block.
9. Install the timing belt lower cover.
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.8 ~ 8.7lb-ft)
Fig. 244: Locating Timing Belt Lower Cover

10. Install the crankshaft damper pulley (A).
Tightening torque
166.7 ~ 176.5Nm (17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft)
Fig. 245: Locating Crankshaft Damper Pulley

11. Install the engine mounting bracket (A).
Tightening torque
63.7 ~ 83.4Nm (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

12. Install the timing belt upper cover (A).
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Fig. 247: Locating Timing Belt Upper Cover
13. Install the drive belt tensioner (C).
Tightening torque
34.3 ~ 53.9Nm (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)
14. Install the drive belt idler and the drive belt (A).
Tightening torque
34.3 ~ 53.9Nm (3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)

15. Install the right side cover.

16. Install the front right wheel and tire.
ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL
CAUTION:
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE:
Mark all wiring and hoses to avoid / Disconnection.
1. Remove the air duct and the battery (A) after disconnecting the terminals (B) from the battery.
Fig. 249: Locating Air Duct And Battery And

Terminals Courtesy of HYUNDAI MOTOR CO.


4. Remove the battery tray (A) while recovering refrigerant.
Fig. 252: Locating Battery Tray

5. Remove the upper radiator hose (A) and lower radiator hose (B).

6. Remove the transaxle oil cooler hoses (A/T vehicles only).

7. Remove the fuel inlet hose (A) from the delivery pipe.


1. Disconnect the No.1/No.2 knock sensor connectors (A,B). the oil pressure switch connector (C), the


connector (B), the No. 1/No.2 OCV (Oil Control Valve) connectors (C,D) and the OTS (Oil Temperature
Sensor) connector (E).


7. Disconnect the bank 2 CMP sensor connector (A) and the WTS (Water Temperature Sensor)
connector (B).

9. Disconnect ground lines (A) from the engine and the transaxle assembly.
Fig. 265: Disconnecting Ground Lines From Engine

10. Disconnect the battery wirings (A,B) from the engine room fuse & relay box (C).
Fig. 266: Disconnecting Battery Wirings

11. Remove the heater hoses.

Fig. 267: Disconnecting Brake Vacuum Hose

13. Disconnect the transaxle wiring harness connectors.(Refer to AUTOMATIC TRANSAXLE (A5HF1) --
SANTA FE or AUTOMATIC TRANSAXLE (F4A51-3) -- SANTA FE ).
14. After draining or gathering power steering fluid, disconnect the power steering hose (A).
Fig. 268: Locating Power Steering Hose

15. Remove the steering column shaft joint bolt.(Refer to STEERING COLUMN AND SHAFT -- SANTA
FE ).
16. Disconnect the air conditioning compressor hoses.(Refer to HEATING, VENTILATION & AIR
17. Remove the front wheels and tires.(Refer to DRIVESHAFT -- SANTA FE ).
18. Lifting the vehicle, remove the under cover.
19. Drain the engine coolant, engine oil and transaxle fluid. Remove the radiator cap to speed coolant
draining.
20. Remove the brake caliper.(Refer to DRIVESHAFT -- SANTA FE ).

21. Disconnect the ABS connectors.(Refer to BRAKE SYSTEM -- SANTA FE ).
22. Disconnect the stabilizer bar link from the struts.(Refer to FRONT SUSPENSION SYSTEM -- SANTA
FE and REAR SUSPENSION SYSTEM -- SANTA FE ).
23. Remove the knuckles from the struts. (Refer to DRIVESHAFT -- SANTA FE ).
24. Remove the front muffler (A).
Fig. 269: Locating Front Muffler

25. Disconnect the power steering return hose.

26. Remove the engine mounting bracket (A).
[MT]

NOTE: Remove the ECM (Electronic Controlled Mounting) nuts and the solenoid
valve connector for A/T vehicles.
27. Remove the transaxle mounting bracket (A).
Fig. 271: Locating Transaxle Mounting Bracket

28. Supporting the engine and transaxle assembly with a jack, remove the assembly from the vehicle by
loosening the subframe mounting bolts and lifting up the vehicle slowly.
NOTE: When removing the engine and transaxle assembly, be careful not to
damage any surrounding parts or body components.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
Adjust the shift cable.

Refill the engine with engine oil.
Refill the transaxle with fluid.
Refill the radiator with engine coolant.
Bleed air from the cooling system with the heater valve open.
Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to
prevent corrosion.
Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel
pump runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.

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What are the specifications of the engine?

What are the specifications of the engine?

What components make up the engine mechanical system?

What components make up the engine mechanical system?

2008 Hyundai Santa Fe SE

2008 ENGINE Engine Mechanical System (G6EA-GSL 2.7) - Santa Fe

Engine Mechanical System (G6EA-GSL 2.7) - Santa Fe

Description Specifications Limit

Type V-type, DOHC

Stroke 75mm (2.9528in.)

Opens (BBDC) 46°

LH Intake 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)

Bearing oil Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in.)

Intake 110.1mm (4.3346in.)

Intake 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.)

MLA (Mechanical Lash Adjuster)

tappet bore inner

Cylinder bore 86.7 ~ 86.73mm (3.4134 ~ 3.4146in.)

Less than 0.03mm (0.0012in.) [Less than

Piston to cylinder clearance 0.02 ~ 0.04mm (0.0008 ~ 0.0020in.)

No. 1 ring groove 1.23 ~ 1.25mm (0.0484 ~ 0.0492in.)

Piston O.S. 0.25mm (0.0098in.) 0.50mm (0.0197in.)

Piston ring O.S. 0.25mm (0.0098in.) 0.50mm (0.0197in.)

Piston pin hole inner diameter 21.014 ~ 21.023mm (0.8273 ~ 0.8277in.)

Type Wax pellet type

Item Quantity Nm kgf.m lb-ft

Oil filter insert 1 44.1 ~ 53.9 4.5~ 5.5 32.5~ 39.8

Intake manifold nut 4 18.6 ~ 23.5 1.9~ 2.4 13.7~ 17.4

6 16.7 ~ 21.6 1.7 ~ 2.2 12.3 ~ 15.9

COMPRESSION PRESSURE INSPECTION

Fig. 1: Identifying Ignition Coil Connectors And Ignition

4. Using a 16mm plug wrench, remove the 6 spark plugs.

Repeat steps 1) through 3) for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

1. Remove the engine cover.

Fig. 2: Identifying Cylinder Head Cover

Courtesy of HYUNDAI MOTOR CO.

Fig. 3: Identifying Timing Marks On Camshaft

NOTE: If not, turn the crankshaft one revolution clockwise.

6. Inspect the intake and the exhaust valve clearance.

Fig. 4: Identifying Intake And Exhaust Valve Clearance

Courtesy of HYUNDAI MOTOR CO.

Limit (Engine coolant temperature : 20°C [68°F])

Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)

Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)

Fig. 5: Identifying Intake And Exhaust Valve

7. Adjust the intake and the exhaust valve clearances.

Fig. 6: Identifying Camshaft Bearing Caps

4. Remove the camshaft assembly.

Fig. 7: Measuring Thickness Of Tappet Using Micrometer

T : Thickness of removed tappet

A : Measured valve clearance

N : Thickness of new tappet

Intake : N = T + [A - 0.20mm (0.0079in.)]

Exhaust: N = T + [A - 0.30mm (0.0118in.)]

NOTE: Tappets are available with 41 different size increments of 0.015mm

9. Place a new tappet on the cylinder head.

10. Install the intake and exhaust camshafts.