XG350 2003 2005 3.5L

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
2003-05 ENGINES
3.5L V6 - XG350
GENERAL
SPECIFICATIONS
General Engine Specifications

Description Specification Limit
General
Type V - type, DOHC
Number of cylinders 6
Bore 93.0 mm (3.661 in.)
Stroke 85.8 mm (3.3779 in.)
Total displacement 3497 cc
Compression ratio 10.0
Firing order 1-2-3-4-5-6
Valve timing
Intake valve
Opens (BTDC) 11.5°
Closes (ABDC) 60.5°
Exhaust valve
Opens (BBDC) 43.5°
Closes (ATDC) 20.5°
Valve overlap 32°
Intake valve duration 252°
Exhaust valve duration 244°
Camshaft
Drive mechanism Cogged type belt
Cam height intake 35.098 ~ 35.298 mm (1.3818 ~
1.3897 in.)
Cam height exhaust 34.81 ~ 35.01 mm (1.3705 ~
1.3783 in.)
Journal diameter 25.951 ~ 25.970 mm (1.0220 ~
1.0224 in.)
Bearing oil clearance 0.05 ~ 0.09 mm (0.0007 ~ 0.0024
in.)
End play 0.1 ~ 0.15 mm (0.0039 ~ 0.0059
in.)
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.05 mm
Flatness of maunting
Surface
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2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Intake Max. 0.10 mm (0.0039 in.) 0.10 mm

Exhaust Max. 0.15 mm (0.0059 in.) 0.15 mm
Valve guide hole diameter
0.05 (0.002) O.S. 12.05 ~ 12.068 mm (0.474 ~ 0.475
in.)
0.25 (0.010) O.S. 12.25 ~ 12.268 mm (0.482 ~ 0.483
in.)
0.50 (0.020) O.S. 12.50 ~ 12.518 mm (0.492 ~ 0.493
in.)
Intake valve seat ring hole
diameter
0.3 (0.012) O.S. 36.30 ~ 36.325 mm (1.429 ~ 1.430
in.)
0.6 (0.024) O.S. 36.60 ~ 36.625 mm (1.441 ~ 1.442
in.)
Exhaust valve seat ring hole
diameter
0.3 (0.012) O.S. 33.30 ~ 33.325 mm (1.311 ~ 1.312
in.)
0.6 (0.024) O.S. 33.60 ~ 33.625 mm (1.323 ~ 1.324
in.)
Valve
Overall length
Intake 106.28 mm (4.184 in.) 105.78 mm (4.164 in.)
Exhaust 105.4 mm (4.150 in.) 104.9 mm (4.130 in.)
Stem diameter
Intake 6.565 ~ 6.580 mm (0.258 ~ 0.259
in.)
Exhaust 6.530 - 6.550 mm (0.257 ~ 0.258
in.)
Face angle 45° ~ 45.5°
Margin
Intake 1.0 mm (0.0394 in.) 0.5 mm (0.0197 in.)
Exhaust 1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
Clearance (stem-to - guide)
Intake 0.02 ~ 0.05 mm (0.0009 ~ 0.0020 0.1 mm (0.0039 in.)
in.)
Exhaust 0.05 ~ 0.085 mm (0.0020 ~ 0.0033 0.15 mm (0.0059 in.)
in.)
Valve spring
Free height 46.4 mm (1.8268 in.) 45.4 mm (1.787 in.)
Load 24.0 kg / 37.9 mm (53 lb / 1.492
in.)
Out of squareness Max 2° 4°
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2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Valve guide
Length
Intake 45.5 mm (1.7913 in.)
Exhaust 50.5 mm (1.9882 in.)
Service oversize 0.05, 0.25, 0.50
Valve seat contact width
Intake 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Exhaust 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Service oversize 0.30, 0.60
Seat angle
Intake 20°
Exhaust 45°
Piston
Diameter (Standard) 92.96 ~ 92.99 mm (3.659 ~ 3.661
in.)
Clearance (Piston-to-cylinder) 0.03 ~ 0.05 mm (0.0012 ~ 0.0020
in.)
Ring groove width
No. 1 1.503 ~ 1.505 mm (0.0592 ~
0.05925 in.)
No. 2 1.501 ~ 1.503 mm (0.0591 ~
0.0592 in.)
Oil 3.010 ~ 3.030 mm (0.1185 ~
0.1193 in.)
Piston for service 0.25 mm (0.010 in.), 0.50 mm
( 0.020 in.)
Oversize
Piston ring
Number of rings per piston 3
Compression ring type 2
Oil ring 1
Compression ring type
No. 1 Barrel type, steel
No. 2 Taper type, special cast iron
Oil ring type 3 - piece type
Ring end gap
No. 1 0.20 ~ 0.30 mm (0.0078 ~ 0.0118
in.)
No. 2 0.45 ~ 0.60 mm (0.0177 ~ 0.0236
in.)
Oil ring side rail 0.2 ~ 0.7 mm (0.0079 ~ 0.0276
in.)
Ring side clearance
No. 1 0.04 ~ 0.08 mm (0.0016 ~ 0.0031
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
in.)
No. 2 0.02 ~ 0.06 mm (0.0008 ~ 0.0024
in.)
Ring for service 0.25 mm (0.010 in.), 0.50 mm
(0.020 in.)
Connecting rod
Side clearance (Big end) 0.10 ~ 0.25 mm (0.0039 ~ 0.0098
in.)
Bend 0.05 mm or less / 100 mm (0.0020
in. or less / 3.937 in.)
Twist 0.1 mm or less /100 mm (0.0039
in. or less / 3.937 in.)
Bearing
Oil clearance 0.026 ~ 0.044 mm (0.001 ~ 0.0017 0.1 mm (0.004 in.)
in.)
Pin diameter 22.001 ~ 22.004 mm (0.8661 ~
0.8663 in.)
Crankshaft
Journal O.D. 63.982 ~ 64.00 mm (2.519 ~
2.5197 in.)
Pin O.D. 54.982 ~ 55.00 mm (2.165 ~
2.1653 in.)
Out - of - roundness of journal and Max. 0.03 mm (0.0012 in.)
pin
Taper of journal and pin Max. 0.005 mm (0.0002 in.)
End play 0.05 ~ 0.25 mm (0.002 ~ 0.0098 0.3 mm (0.012 in.)
in.)
Main bearing
Oil clearance 0.022 ~ 0.040 mm (0.00086 ~
0.00157 in.)
Cylinder block
Cylinder bore 93 mm (3.661 in.)
Flatness of gasket surface Max. 0.05 mm (0.002 in.)
Out - of - roundness and taper Max. 0.02 mm (0.0008 in.) 0.05 mm (0.002 in.)
Oil pump
Body clearance 0.100 ~ 0.181 mm (0.0039 ~
0.0071 in.)
Side clearance 0.040 ~ 0.095 mm (0.0016 ~
0.0037 in.)
Tip clearance 0.06 ~ 0.018 mm (0.0024 ~ 0.0071
in.)
Relief spring
Free length 46.3 mm (1.823 in.)
Load 6.9 kg/39.1 mm (15.18 lb. / 1.54
in.)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Oil filter
Type Cartridge, full flow
Engine oil pressure 80 kPa (11.4 psi) or more @700
rpm [Conditions : Oil temperature
is 75 to 90°C (167 to 194°F)]
Cooling method Engine coolant cooling, forced
circulation with electric fan
Cooling system
Quantity 8.2 lit (8.61 U.S.qts., 7.2 lmp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 82°C (179.6°F)
Opening temperature range 80°C ~ 84°C (176 ~ 183.2°F)
Wide open temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 86.1 ~ 124.5 kPa (0.98 ~ 1.27
kg/cm2 , 13.94 ~ 18.06 psi)
Main valve closing pressure 83.4 kPa (0.85 kg/cm2 , 12.1 psi)
Vacuum valve opening pressure - 6.86 kPa (- 0.07 kg/cm2 , - 1.00
psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
SERVICE STANDARD
Standard value
Coolant concentration
Tropical area: 40%
Other area: 50%
LUBRICANT
Engine coolant: Ethylene glycol base for aluminum radiator
SEALANT
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 1: Identifying Engine Coolant Temperature Sensor Sealant

Courtesy of HYUNDAI MOTOR CO.
TIGHTENING TORQUE
TORQUE SPECIFICATIONS
Application Ft. Lbs (N.m)
Air Intake Tank-To-Manifold Fasteners 11-15 (15-20)
Auto Tensioner Fixed Bolt 15-20 (20-27)
Camshaft Bearing Cap (1)
Inner (2)
Outer 14-15 (19-20)

Camshaft Sprocket Bolt 59-74 (80-100)
Connecting Rod Nut
Step 1 25 (34)
Step 2 Tighten An Additional 90 Degrees
Coolant Inlet Fitting Bolt 13-15 (17-20)
Coolant Pump Bolt (Bolt Head Mark "7")
M8 11-16 (15-22)
M10 24-37 (33-50)
Coolant Temperature Sensor 15-30 (20-40)
Crankshaft Bolt 133-140 (180-190)
Crankshaft Pulley Bolt 133-140 (180-190)
Cylinder Head Bolt (Cold) (3) 77-85 (105-115)
Drive Belt Pulley Bolt 26-41 (35-55)
Drive Belt Tensioner Nut 24-41 (35-55)
Drive Plate & Adapter Plate Bolt 54-57 (73-77)
Engine Hanger Bracket Bolt 20-28 (27-38)
Engine Mounting Fasteners
Engine Mounting Bracket Bolt 44-59 (60-80)
Engine Mounting Bracket Nut 44-59 (60-80)
Engine Mounting Insulator Bolt 66-81 (90-110)
Front Roll Stopper Bracket-To-Transaxle Bolt 44-59 (60-80)
Front Roll Stopper Insulator Fasteners
Front Roll Stopper Bracket-To-Subframe Bolt 44-59 (60-80)
Rear Roll Stopper Bracket-To-Subframe Bolts 44-59 (60-80)
Rear Roll Stopper Bracket-To-Transaxle Bolts 37-41 (50-65)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Rear Roll Stopper Insulator Bolt & Nut 37-41 (50-65)

Exhaust Components
Catalytic Converter-To-Center Exhaust Pipe Nut 22-30 (30-40)
Center Exhaust Pipe-To-Main Muffler Nuts 22-30 (30-40)
Exhaust Manifold-To-Cylinder Head Nut 30-37 (40-50)
Exhaust Manifolt-To-Engine 30-33 (40-45)
Front Exhaust Pipe-To-Catalytic Converter Bolt 30-44 (40-60)
Front Exhaust Pipe-To-Exhaust Manifold Bolt 22-30 (30-40)
Generator Mounting Bracket Bolt (All) 15-22 (20-30)
Intake Manifold-To-Cylinder Head Nuts (4) 15-17 (20-23)
Main Bearing Bolt (5) 66-74 (90-100)
Oil Drain Plug 26-33 (35-45)
Oil Filter 9-12 (12-16)
Oil Pump Case Bolt 11-15 (15-20)
Oil Pump Relief Valve Plug 30-37 (40-50)
Oil Screen Bolt 11-16 (15-22)
Oxygen Sensor 30-37 (40-50)
Power Steering Bracket-To-Cylinder Head Bolt 13-15 (17-26)
Power Steering Pump-To-Bracket bolt 13-15 (17-26)
Starter-To-Engine Bolt 20-25 (27-34)
Starter-To-Engine Nut 15-22 (20-30)
Surge Tank Stay Bolt 11-15 (15-20)
Throttle Body-To-Surge Tank Bolts 18-22 (25-30)
Timing Belt Cover Bolt
M6 (2)
M8 15-20 (20-27)
Timing Belt Idler Pulley Bolt 37-44 (50-60)
Timing Belt Tensioner Arm Fixed Bolt 26-41 (35-55)
Timing Belt Tensioner Bolt 15-20 (20-27)
Timing Belt Tensioner Pulley Bolt 32-41 (43-55)
Transaxle Mounting Fasteners
Transaxle Mounting Bracket Bolts 44-59 (60-80)
Transaxle Mounting Insulator Bolt 66-81 (90-110)
Transaxle Mounting Sub Bracket Nut 44-59 (60-80)
Upper Oil Pan Bolt (6)
10x380 mm 22-31 (30-42)
6x18 mm (7)
6x161.5 mm (7)
6x152.5 mm (7)
Water Outlet Fitting Bolt 13-15 (17-20)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
INCH Lbs. (N.m)

Air Cleaner Body Installation Bolt 71-106 (8-12)
Air Cleaner Mounting Bolt 71-106 (8-12)
Crankshaft Position Sensor Wheel Screw 97-106 (11-12)
Cylinder Head Cover Bolt 44-53 (5-6)
Delivery Pipe Installation Bolt 89-133 (10-15)
Fuel Hose Clamp-To-Engine Bolt 106-133 (12-15)
Generator Inlet Pipe Bolt 106-133 (12-15)
Heat Protector-To-Exhaust Manifold 106-133 (12-15)
Lower Oil Pan Bolt (8) 89-106 (10-12)
Main Muffler Hanger Support Bracket Bolt 89-133 (10-15)
Oil Level Guide-To-Engine 106-133 (12-15)
Oil Pressure Switch 71-133 (8-15)
Oil Pump Cover Screw 71-106 (8-12)
Oil Seal Case 89-106 (10-12)
Rear Plate 89-106 (10-12)
Transaxle Mounting Plate 89-106 (10-12)
(1) Tighten camshaft bearing cap bolts in sequence. See Fig. 97.
(2) Tighten to 89-106 INCH Lbs. (10-12).

(3) Tighten cylinder head bolts in sequence. See Fig. 15.
(4) Tighten intake manifold nuts in sequence. See Fig. 151.
(5) Tighten main bearing bolts in sequence. See Fig. 116.
(6) Tighten upper oil pan bolts in sequence. See Fig. 131.
(7) Tighten to 44-62 INCH Lbs. (5-7 N.m).
(8) Tighten lower oil pan bolts in sequence. See Fig. 133.
CHECKING ENGINE OIL
1. Position a vehicle on a level surface.

2. Turn off the engine.
NOTE: In the case of a vehicle that has not been used for a prolonged period, run
the engine for several minutes. Turn off the engine and wait for 5 minutes
at least, then check the oil level.
3. Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is
found to have fallen to the lower limit (the "L" mark), refill to the "F" mark.
NOTE: When refilling, use the proper grade of engine oil.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
4. Check that the oil is not dirty or mixed with coolant or gasoline, and that it has the proper viscosity.
Fig. 2: Identifying Engine Oil Operating Range On Engine Oil Dipstick

SELECTION OF ENGINE OIL
Recommended API classification: SH OR ABOVE [For EC.]
Recommended SAE viscosity grades:
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 3: Identifying Recommended SAE Oil Viscosity Grades

NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which:
1. Satisfy the requirements of the API classification.

2. Have the proper SAE grade number for expected ambient temperature
range.
Lubricants which do not have both an SAE grade number and an API service classification on the container
should not be used.
CHANGE ENGINE OIL
1. Run the engine until if reaches normal operating temperature.

2. Turn off the engine.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
3. Remove the oil filler cap and oil filter and then drain plug.
Drain the engine oil.
4. Tighten the drain plug to the specified torque.
Tightening torque
Oil pan drain plug:
35 ~ 45 Nm (350 ~ 450 kg.cm, 25 ~ 33 lb. ft)
NOTE: Whenever tightening the oil drain plug, use a new drain plug gasket.
Fig. 4: Identifying Engine Oil Drain Plug & Seal

5. Fill the new engine oil through the oil filler cap.
Drain and refill
Oil quantity: 4.3 lit (4.5 U.S. qts., 3.8 lmp. qts.)
NOTE: Do not over fill. This will cause oil aeration and loss of oil pressure.
6. Install the oil filler cap.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
7. Start and run the engine.

8. Turn off the engine and then check the oil level. Add oil it necessary.
REPLACEMENT OIL FILTER
FILTER SELECTION
All Hyundai Motor Company engines are equipped with a high quality, disposable oil filter. This filter is
recommended as a replacement filter for all vehicles. The quality of after market replacement filters is various
considerably.
High quality of replacement filters should be used to assure the most efficient service. Make sure that the rubber
gasket from the old oil filter is completely removed from the contact surface on the engine block before
installing a new filter.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 5: Identifying Engine Oil Filter Part Number Location

PROCEDURE FOR REPLACING OIL FILTER
1. Use a filter wrench to remove the oil filter.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 6: Locating Engine Oil Filter

2. Before installing a new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. Tighten the oil filter of the specified torque.
Tightening torque
Oil filter: 12 ~ 16 Nm (120 ~ 160 kg.cm, 8.7 ~ 11.6 lb. ft)
4. Start and run the engine and check engine oil leaks.
5. After stopping the engine, check the oil level and add oil as necessary.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 7: Identifying & Lubricating Engine Oil Filter Seal

CHECKING COOLANT LEAK CHECK
1. Loosen the radiator cap.

2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 150 KPa (21psi, 1.53 kg/cm2 ) pressure.
Hold for two minutes, then check for leakage from the radiator, hoses or connections.
CAUTION: 1. Radiator coolant may be extremely hot. Do not open the system
while hot, or scalding engine coolant could gush out, causing
personal injury. Allow the vehicle to cool before servicing this
system.
2. When the tester is removed, be careful not to spill any coolant
from it.
3. Be sure to clean away completely any coolant from the area.
4. Be careful, when installing and removing the tester and when
testing, not to deform the filler neck of the radiator.
4. If there is leakage, repair or replace with the appropriate part.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 8: Pressure Testing Cooling System

RADIATOR CAP PRESSURE TEST
1. Use an adapter to attach the cap to the tester.

2. Increase the pressure until the indicator of the gauge stops moving.
Main valve opening pressure:
107.9 +/- 14.7 kPa (1.1 +/- 0.15 kg/cm2 , 15.64 +/- 2.13 psi)
Main valve closing pressure:
83.4 kPa (0.85 kg/cm2 , 12.1 psi)
3. Check that the pressure level is maintained at or above the limit.

4. Replace the radiator cap if the reading does not remain at or above the limit.
NOTE: Be sure that the cap is clean before testing, since rust or other foreign
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
material on the cap seal will cause an incorrect reading.
Fig. 9: Pressure Testing Radiator Pressure Cap

SPECIFIC GRAVITY TEST
1. Measure the specific gravity of the coolant with a hydrometer.

2. Measure the coolant temperature and calculate the concentration from the relation between the specific
gravity and temperature. Use the following table for reference.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 10: Measuring Coolant Specific Gravity

RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Fig. 11: Identifying Relationship Between Coolant Concentration & Specific Gravity
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
EXAMPLE
The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at coolant
temperature of 20°C (68°F)
CAUTION: If the concentration of the coolant is below 30%, its anti-corrosion

property will be adversely affected.
If the concentration is above 60%, the engine cooling property will
decrease, affecting the engine adversely. For these reasons, be sure
to maintain the concentration level within the specified range.
Do not mix types of anti - freeze.
RECOMMENDED COOLANT
Fig. 12: Identifying Recommended Coolant Mixing Ratios

CHECKING COMPRESSION PRESSURE
1. Before checking the engine compression, check the engine oil level. Also check that the starter motor and
battery are all in normal operating condition.
2. Start the engine and wait until the engine coolant temperature reaches 80-95°C (176~205°F).
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5. Crank the engine to remove any foreign material in the cylinders.
6. Insert the compression gauge into the spark plug hole.
7. Depress the accelerator pedal to open the throttle fully.
8. Crank the engine and read the gauge.
Standard value: 1,200 kpa (12.2 kg/cm2 , 170 psi)
Limit: 1,050 kpa (10.7 kg/cm2 , 149 psi)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 13: Checking Engine Compression With Compression Gauge

9. Repeat steps 6 to 8 for all cylinders, making sure that the pressure difference for each of the cylinders is
within the specified limit.
Limit:
Max. 100 kpa (1.0 kg/cm2 , 14 psi) between cylinders
10. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil
through the spark plug hole, and repeat steps 6 to 9.
1. If the addition of oil causes the compression to rise, it is possible that the piston ring is worn.
2. If the compression remains the same, valve seizure, poor valve seating or a compression leak in the
cylinder head gasket are all possible causes.
Tightening torque
Spark plug: 20 ~ 30 Nm (200 ~ 300 kg.cm, 14 ~ 22 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
TIGHTENING CYLINDER HEAD BOLTS
1. First loosen slightly and then tighten to the specified torque.
Tightening torque
Cylinder head bolts cold [Engine temperature approximately 20°C (68°F)]:
105 ~ 115 Nm (1050 ~ 1150 kg.cm, 75 ~ 82 lb. ft.)
Fig. 14: Tightening Cylinder Head Bolts With Torque Wrench

2. Be sure to follow the specific torque sequence as shown in the illustration.
NOTE: Run the engine to normal operating temperature and let it cool, then re-torque
the bolts to specifications.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 15: Identifying Cylinder Head Tightening Sequence

ADJUSTING VALVE CLEARANCE
As the intake and exhaust valves are equipped with hydraulic lash adjusters, there is no need to adjust the valve
clearance. The proper function of the hydraulic lash mechanism may be determined by checking for tappet
noise. When there is a tappet noise or any unusual noise, check the hydraulic lash adjuster by removing and
bleeding or replacing it.
ADJUSTING DRIVE BELT AND TENSIONER
1. Hang the belt on the pulley of the tensioner and install the tensioner.
(If the tensioner is already installed, loosen its mounting nut to allow belt installation.)
Tightening torque
Tensioner assembly nut:
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
35 ~ 55 Nm (350 ~ 550 Kg. cm, 26 ~ 40 lb. ft)
Fig. 16: Identifying Engine & Power Steering Drive Belts & Components
2. Install power steering belt.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 17: Installing Power Steering Belt

3. Install drive belt.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 18: Installing Drive Belt

4. Adjust the power steering belt tension to specification by turning the adjusting bolt (Q) clockwise or
counterclockwise.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 19: Adjusting Power Steering Belt

5. Adjust the drive belt tension to specification by turning the adjusting bolt (Q) clockwise or
counterclockwise.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 20: Adjusting Drive Belt

6. When installing the belt on the pulley, make sure it is centered on the pulley.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 21: Identifying Proper Belt-To-Pulley Fit

ENGINE AND TRANSAXLE ASSEMBLY
REMOVAL
1. Remove the battery and engine cover.

2. Remove the battery stay.
3. Detach the air cleaner.
4. Disconnect the connectors from the engine harness.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 22: Disconnecting Air Cleaner

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 23: Disconnecting Engine Electrical Connectors

1. Alternator, starter
2. Power steering switch connector, oil pressure gauge connector, air conditioner switch
3. Injector connectors
4. Back up lamp switch connector
5. A/T solenoid, inhibitor switch connector.
6. Coolant temperature
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 24: Identifying Engine Coolant Temperature (ETC) Sensor

7. Ignition coils, power TR connector

8. Idle speed control valve (ISC) connector
9. AFS and ATS connectors
10. Oxygen sensor connector etc.
5. Disconnect the transaxle oil cooler hoses (A/T).
NOTE: When disconnecting hoses, make identification marks to avoid making

any mistake when installing them again.
CAUTION: Be careful not to spill any of the oil or fluid from the hoses. Plug the
openings to prevent the entry of foreign material.
6. Disconnect the radiator upper and lower hoses on the engine side.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 25: Disconnecting Radiator Hoses

7. Disconnect the engine ground and transaxle ground.

8. Disconnect the brake booster vacuum hose.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 26: Disconnecting Brake Booster Hose

9. Disconnect the heater hoses (inlet and outlet) on the engine side.
10. Remove the main fuel line (supply and return) at the delivery pipe.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 27: Disconnecting Fuel Lines At Delivery Pipe

11. Disconnect the speedometer cable from the transaxle.

12. Disconnect the control cable from the transaxle.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 28: Disconnecting Transmission Control Cable

13. Remove the power steering oil pump.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 29: Removing Power Steering Oil Pump

14. Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint
bolt.
NOTE: Make sure to make identification marks between the universal joint and the
gear box for reassembly.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 30: Disconnection Steering Gear Box Universal Joint

15. Raise the vehicle and then remove the front tire.
16. Remove the caliper assembly from knuckle and hold the upper side.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 31: Supporting Brake Caliper Assembly

17. Remove the lower arm ball joint bolts and upper arm bolt from the knuckle.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 32: Removing Lower Arm Ball Joint Bolts From Knuckle
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 33: Removing Upper Arm Bolts From Knuckle

18. Remove the wheel speed sensor from the knuckle.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 34: Removing Wheel Speed Sensor

19. Remove the front muffler bolts.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 35: Removing Front Muffler Bolts (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 36: Removing Front Muffler Bolts (2 Of 2)

20. Put the special fixture on the T/M jack and then adjust it to the sub - frame.
NOTE: Check that all the cables, harness connector and hoses are disconnected
from the engine and transaxle assembly.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 37: Identifying T/M Jack

21. Remove the engine mount bolts.
Fig. 38: Removing Engine Mount Bolts

22. Remove the transaxle mounting bracket bolts.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 39: Removing Transaxle Bracket Mounting Bolts

23. Remove the cross member fixing bolts.

24. While directing the transaxle side downward, lift the engine and transaxle assembly down and out of the
vehicle.
INSTALLATION
Installation is the reverse order of removal.
SPECIAL TOOLS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 40: Special Tools (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 41: Special Tools (2 Of 2)

TROUBLE SHOOTING
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 42: Trouble Shooting Table (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 43: Trouble Shooting Table (2 Of 2)

TIMING SYSTEM
TIMING BELT
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 44: Identifying Timing Belt & Related Components

REMOVAL
1. Remove the wheel of passenger side.

2. Remove the side cover.
3. Remove the engine cover.
4. Disconnect the power steering hose fixing on the engine mounting bracket.
5. Remove the engine mounting bracket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 45: Removing Engine Mounting Bracket

CAUTION: Before removing the engine mounting bracket support the engine oil
pan with a jack or equivalent so as not to go down the engine.
6. Disconnect the connectors from the timing belt upper cover and remove the upper cover.
7. Remove the drive belt and loosen the 2 alternator mounting nuts (14 mm) and 2 bolts (12 mm) connecting
the engine support bracket.
8. Loosen the 5 engine support bracket bolts.
CAUTION: To loosen the bolt shown in the forward of engine, first disconnect
the alternator.
9. Remove the engine support bracket bolt by moving the engine up and down slightly and remove the
bracket upward.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
10. Remove the auto tensioner.
Fig. 46: Removing The Timing Belt Auto Tensioner

NOTE: Rotate the crankshaft clockwise and align the timing mark to set the No. 1
cylinder's piston to TDC (compression stroke).
At this time, the timing marks of the camshaft sprocket and cylinder head
cover should coincide with each other.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 47: Rotating Engine To Align Timing Marks

11. Unbolt the tensioner to remove the timing belt.
NOTE: If you plan to use the timing belt again, mark the rotation direction on the
belt so you reinstall it correctly.
INSPECTION
1. Inspect the belt closely. If the following problems are evident, replace the belt with a new one.
1. Hardened back surface of rubber
Back surface is glossy, non-elastic and so hard that when the nail of your finger is pressed into it,
no mark is produced.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 48: Checking Timing Belt Hardness

2. Cracked back surface of rubber.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 49: Checking Timing Belt For Cracks

3. Side of belt is badly worn.
NOTE: A belt in good condition should have clear-cut sides as if it were cut
with a sharp knife.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 50: Checking Timing Belt Condition

4. Teeth are badly worn out.
Initial stage: Canvas on load side of the tooth flank worn (fluffy canvas fibers, rubber gone, color
changed to white, and unclear canvas texture)
Last stage: Canvas on the load side of the tooth flank worn down and rubber exposed (tooth width
reduced).
5. Missing tooth
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 51: Checking Timing Belt For Tooth Wear

2. If backlash or an irregular noise is observed when rotating the pulley, replace the timing belt tensioner
and idler pulley.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 52: Checking Timing Belt Tensioner Condition

COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 53: Identifying Timing System Components & Timing Mark Alignment
INSTALLATION
The method of installing timing belt and auto tensioner.
1. Install idler pulley to engine support lower bracket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 54: Installing Idler Pulley To Engine Support Lower Bracket
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
2. Install tensioner arm, shaft and plane washer to cylinder block.
Tightening torque: 35 ~ 55 Nm (350 ~ 550 kg.cm)
Fig. 55: Installing Tensioner Arm Shaft & Plane Washers

3. Install crankshaft sprocket and align the timing mark.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 56: Identifying Crankshaft Sprocket Timing Marks

CAUTION: Be careful not to bend crankshaft sensing blade.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 57: Installing Crankshaft Sprocket, Sensing Blade & Spacer

4. Install camshaft sprocket and adjust initial installation state as illustration.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 58: Identifying Initial Camshaft Installation Positions

5. Install auto tensioner to oil pump case.
NOTE: If the auto tensioner rod is in its fully extended position, reset it as follows.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 59: Installing Timing Belt Auto-Tensioner To Oil Pump Case

1. Clamp it in a vise equipped with soft jaws, in a level position. Use a plain washer if there is a plug
at the bottom of the auto tensioner.
2. Compress the rod slowly with the vise until the set hole in the rod is aligned with set hole in the
cylinder.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 60: Aligning Timing Belt Tensioner Set Hole In Rod With Set Hole In Tensioner Body
3. Insert a set pin through the auto tensioner body and rod.
CAUTION: Leave the set pin installed in the auto tensioner.
6. Align the timing marks of each sprocket and install the timing belt in this order.
Crankshaft sprocket --> Idler pulley --> Exhaust camshaft sprocket (LH) --> Intake camshaft sprocket
(RH) --> Exhaust camshaft sprocket (RH) --> Tensioner pulley.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 61: Installing Timing Belt To Pulleys & Sprockets

NOTE: In this step, No. 1 is in TDC (Compression stroke)

Do not insert fingers.
7. After installing the timing belt, reconfirm the timing mark.

8. Pull out the set pin of auto tensioner.
NOTE: 1. Rotate the crankshaft 2 rotation clockwise and measure the projected
load of auto tensioner in the TDC (# 1 compression stroke) after 5
minutes.
2. Check the projected length is 3.8 ~ 4.5 mm.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
3. Check again if the timing marks of each sprocket is with in specified

position.
9. Install the engine support bracket.

10. Install the timing belt cover.
11. Install the alternator and drive belt.
12. Install the engine mounting bracket.
13. Install the side cover.
14. Install the wheel of passenger side.
CYLINDER HEAD ASSEMBLY

CYLINDER HEAD
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 62: Identifying Cylinder Head Components

DISASSEMBLY
1. Remove the engine. For additional information, refer toENGINE AND TRANSAXLE ASSEMBLY.
2. For additional information, refer to INTAKE MANIFOLD.
3. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
4. Remove the ignition coil.
5. Remove the upper and lower timing belt cover.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 63: Removing Upper & Lower Timing Belt Covers

6. Remove the timing belt and camshaft sprockets. For additional information, refer to TIMING BELT.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 64: Removing Timing Belt

7. Remove the heat protector and exhaust manifold assembly.

8. Remove the coolant pump pulley and head cover.
9. Remove the intake and exhaust camshaft. For additional information, refer to CAM SHAFT.
10. Remove the cylinder head assembly. The cylinder head bolts should be removed using the 12 mm socket,
in two or three steps.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 65: Removing Cylinder Head Bolts

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 66: Cylinder Head Bolt Removal Sequence

11. Clean the gasket pieces from the cylinder block top surface and cylinder head bottom surface.
NOTE: Make sure that fragments from the gasket do not fall in the engine.
RETAINER LOCK
1. Compress the valve spring using special tool. (09222 - 28000, 09222 - 28100)
2. Remove the retainer lock.
Fig. 67: Compressing Valve Springs & Removing Retainers

3. Remove the valve spring, valve spring retainer valve spring sheet and valve.
INSPECTION
CYLINDER HEAD
1. Remove scale, sealing compound and carbon deposits. After cleaning oil passages, apply compressed air
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
to make certain that the passages are not clogged.

2. Visually check the cylinder head for cracks, damage or water leakage.
3. Check the cylinder head surface for flatness with a straight edge and feeler gauge as shown in the
illustration.
Cylinder head flatness
Standard dimensions: Max. 0.03 mm (0.0059 in.)
Service limit: 0.05 mm (0.0020 in.)
Fig. 68: Checking Cylinder Head Surface For Flatness

VALVE GUIDES
Check the valve stem - to - guide clearance. If the clearance exceeds the service limit, replace the valve guide
with a new oversize guide.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Valve stem-to-guide clearance
Standard value
Intake: 0.02 ~ 0.05 mm (0.0009 ~ 0.0020 in.)
Exhaust: 0.050 ~ 0.085 mm (0.0020 ~ 0.0033 in.)
Fig. 69: Measuring Valve Stem Clearance

VALVE
1. Replace the valve if its stem is bent, worn or damaged. Also replace it if the stem end (the surface
contacting the hydraulic-lash adjuster) is hollowed out.
2. Check the valve face contact area, and recondition or replace as necessary.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 70: Inspecting Valve For Straightness, Wear & Damage

3. Replace the valve if the width of the margin (thickness of the valve head) is less than the minimum
specified.
Valve margin
Standard value
Intake: 1.0 mm (0.0394 in.)
Exhaust: 1.3 mm (0.0512 in.)
Fig. 71: Inspecting Valve Margin

VALVE SPRING
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
1. Check the free height of each valve spring and replace if necessary.
2. Using a square, test the squareness of each valve spring. If the spring is excessively out-of-square, replace
it.
Valve spring
Standard value
Free height: 46.4 mm (1.8268 in.)
Load: 24 kg/37.9 mm (53 lb/1.492 in.)
Out - of - square: Max. 2°
Service limit
Free height: .45.4 mm (1.787 in.)
Out - of - square: Max. 4°
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2003-05 ENGINES 3.5L V6 - XG350
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 72: Checking Valve Spring Squareness & Free Height

REPLACING VALVE GUIDE
1. Using the special tool (09222-22000 B), withdraw the old valve guide out the bottom of the cylinder
head.
2. Recondition the valve guide hole so that it can receive the newly press-fitted oversize valve guide.
VALVE GUIDE OVERSIZES
Fig. 73: Oversized Valve Guide Table

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 74: Press Fitting Valve Guide Into Position

3. Using the special tool (09221-29000(A), 09222-22000(B)) press-fit the valve guide. The valve guide
must be press-fitted from the upper side of the cylinder head. Keep in mind that the intake and exhaust
valve guides are different in length.
4. After the valve guide is press-fitted, insert a new valve and check for proper clearance.
5. After the valve guide is replaced, check that the valve is fully seated. Recondition the valve seats as
necessary.
NOTE: Do not install a valve guide unless it is oversize.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 75: Identifying Exhaust & Intake Valve Guides

REPLACING VALVE SEAT RING
1. Cut away the inner face of the valve seat to reduce the wall thickness.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 76: Identifying Area To Be Cut Away For Valve Seat Ring Replacement
2. Enlarge the diameter of the valve seat so that it matches the specified hole diameter of the new valve seat
ring.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 77: Matching Valve Seat Ring Replacement To Hole Size

VALVE SEAT RING OVERSIZES
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 78: Valve Seat Ring Oversize Table

3. Heat the cylinder head to about 250°C (480°F) and press-fit an oversize seat ring for the bore in the
cylinder head.
4. Using lapping compound, lap the valve to the new seat.
Valve seat contact width
Intake: 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
Exhaust: 0.9 ~ 1.3 mm (0.035 ~ 0.051 in.)
REASSEMBLY
1. Install the spring seats.

2. Using special tool (09222-28200), lightly tap the seal in position.
NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage of from the
valve guides.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 79: Identifying Valve Stem Seal

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 80: Installing Valve Spring Seal

3. Apply engine oil to each valve. Insert the valve into their guides. Avoid pushing the valve into the seal by
force. After installing the valve, check that it moves smoothly.
4. Place valve springs so that the side coated with enamel faces toward the valve spring retainer.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 81: Identifying Valve Spring Positioning

5. Using the special tool (09222 - 28000, 09222 - 28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve
spring compressor.
NOTE: When the spring is compressed, check that the valve stem seal is not
pressed against the bottom of the retainer.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 82: Installing Valve Assembly

6. Clean both gasket surfaces of the cylinder head and cylinder block.
7. Verify the identification marks on the cylinder head gasket.
8. Install the gasket so that the surface with the identification mark faces toward the cylinder head.
NOTE: Do not apply sealant to these surfaces.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 83: Identifying Cylinder Head Gasket

9. Tighten the cylinder head bolts in the sequence shown in the illustration with a torque wrench.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 84: Tightening Cylinder Head Bolts

10. Tighten the cylinder head bolts. Starting at top center, tighten all cylinder head bolts in sequence as
shown in the illustration, using the 12 mm socket.
Tightening procedure
Cylinder head bolt:
105 ~ 115 Nm (1050 ~ 1150 kg.cm, 75 ~ 82 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 85: Cylinder Head Bolt Tightening Sequence

MAIN MOVING SYSTEM

CAM SHAFT
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 86: Identifying Camshaft Components

DISASSEMBLY
1. Remove the engine cover and intake manifold
For additional information, refer to the INTAKE MANIFOLD.
2. Disconnect the breather hose and the engine harness.
For additional information, refer to the ENGINE AND TRANSAXLE ASSEMBLY.
3. Remove the timing belt.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
For additional information, refer to the TIMING BELT.
4. Remove the spark plug cables.

5. Loosen the cylinder head cover bolts and then remove it.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 87: Identifying Cylinder Head Cover Bolts

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
6. Remove the camshaft sprockets.

7. Remove the camshaft bearing caps.
Fig. 88: Removing Camshaft Bearing Caps

8. Remove the camshafts.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 89: Removing Camshaft

INSPECTION
CAMSHAFTS
1. Check the camshaft journals for wear. If the journals are badly worn out, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is damaged or excessively worn out, replace the camshaft.
Cam height
Standard
Intake: 35.098 ~ 35.298 mm (1.3818 ~ 1.3897 in.)
Exhaust: 34.81 ~ 35.01 mm (1.3705 ~ 1.3783 in.)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 90: Measuring Camshaft For Wear

3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head
assembly or camshaft bearing cap, as necessary.
Camshaft end play:
0.1 ~ 0.15 mm (0.0039 ~ 0.0059 in.)
OIL SEAL (CAMSHAFT FRONT)
1. Check the lips for wear. If lip threads are worn out, replace the oil seal with new one.
2. Check a contact surface of oil seal lip on camshaft. If there stratified wear, replace the camshaft.
HLA (HYDRAULIC LASH ADJUSTER)
With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 91: Checking Hydraulic Lash Adjuster

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 92: Hydraulic Lash Adjuster Symptom Table

AUTO LASH ADJUSTER
1. Check auto - lash adjusters for free play by inserting a small wire through the air bleed hole in the rocker
arm and push the autolash adjuster check ball down very lightly.
2. While lightly holding the check ball down move the rocker arm up and down to check for free play. If
there is no play replace the auto - lash adjuster.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 93: Checking Hydraulic Lash Adjuster Free Play

REASSEMBLY
CAMSHAFT AND BEARING CAP
1. Rotate the crankshaft and No. 1 cylinder is in TDC (Compression stroke)

2. Check the position of the rocker arm whether it is exactly installed on the lash adjuster and valve or not.
3. Install the camshaft dowel pin as illustration.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 94: Camshaft Installation Positions

4. The left and right banks of the camshafts are different and you should be careful not to confuse them.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Identification signal
Left bank
Intake (IN): F
Exhaust (Ex): E
Right bank
Intake (IN): G
Exhaust (Ex): H
Fig. 95: Identifying Camshaft Size Difference Between Left & Right Cylinder Banks
5. Confirm the identification mark and the number. Bearing caps of No. 3, No. 4, and No. 5 have the front
mark and arrange the front mark upon the cylinder head while installing the bearing caps.
Identification mark
Intake: I
Exhaust: E
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 96: Identifying Camshaft Bearing Cap Markings

6. Tighten the bearing cap by 2 or 3 steps
Tightening Torque
Outer (*) 16 EA: 1.9 ~ 2.1 kg.m
Inner 24 EA: 1.0 ~ 1.2 kg.m
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 97: Identifying Camshaft Bearing Cap Tightening Sequence

CONNECTING ROD
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 98: Identifying Connection Rod Components

REMOVAL
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
1. Remove the timing belt.
For additional information, refer to TIMING BELT.
2. Remove the cylinder head.
For additional information, refer to CYLINDER HEAD.
3. Remove the oil pan.

4. Remove the oil screen.
5. Remove the upper baffle plate.
DISASSEMBLY
CONNECTING ROD CAP
CAUTION: Keep the bearings in order with their corresponding connecting rods
(according to cylinder numbers) for proper reassembly.
1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing mark for
reassembly.
2. Push each piston connecting rod assembly toward the top of the cylinder.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 99: Identifying Connecting Rod Caps

INSPECTION
PISTONS AND PISTON PINS
1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
2. Check each piston ring for breakage, damage and abnormal wear. Replace the defective rings. When the
piston requires replacement, its rings should also be replaced.
3. Check that the piston pin fits in the piston pin hole. Replace any piston and pin assembly that is defective.
The piston pin must be pressed smoothly by hand into the pin hole (at room temperature).
PISTON RINGS
1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring
in the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the
piston and rings together. If it is less than the service limit, replace only the piston rings.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Piston ring side clearance
No. 1: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
No. 2: 0.45 ~ 0.60 mm (0.018 ~ 0.024 in.)
Oil ring side rail: 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.)
2. 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.
PISTON RING END GAP
Standard dimensions
No. 1: 0.2 ~ 0.3 mm (0.0078 ~ 0.0118 in.)
No. 2: 0.45 ~ 0.60 mm (0.018 ~ 0.024 in.)
Oil ring side rail: 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.)
When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the lower
part of cylinder that is less worn out.
PISTON RING SERVICE SIZE AND MARK
Fig. 100: Piston Ring Service Size Table

NOTE: The mark can be found on the upper side of the ring next to the end.
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2003-05 ENGINES 3.5L V6 - XG350
Fig. 101: Piston & Ring Assembly

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2003-05 ENGINES 3.5L V6 - XG350
CONNECTING RODS
1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at
disassembly, match. When a new connecting rod is installed, make sure that the notches holding the
bearing in place are on the same side.
2. Replace the connecting rod if it is damaged at either end of the thrust faces. If it has a stratified wear, or if
the surface of the inside diameter of the small end is severely rough, replace the rod.
Fig. 102: Identifying Proper Bearing Notch Position

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2003-05 ENGINES 3.5L V6 - XG350
REASSEMBLY
1. Install the spacer.
Fig. 103: Identifying Oil Ring Components

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 104: Identifying Piston Oil Ring End Gap Locations

2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring
groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove
(as illustrated).
CAUTION: Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure described in Step 2.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 105: Installing Piston Oil Ring Side Rail

4. Apply engine oil around the piston and piston grooves.

5. Using a piston ring expander, install the No. 2 piston ring.
6. Install the No. 1 piston ring.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 106: Installing Piston Rings No. 1 & 2

7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the
gaps are not positioned in the thrust and pin directions.
8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
Fig. 107: Identifying Piston Ring End Gap Locations

9. Install the upper main bearings in the cylinder block.

10. Install the lower main bearings in the main bearing caps.
CAUTION: Install the bearing so it matches the oil hole in the block.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 108: Installing Upper Main Bearings

11. Install the thrust washers in the No. 3 main bearing cap with the oil grooves facing outward.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 109: Installing Main Bearing Thrust Washers

12. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod
are directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap
at disassembly match.
14. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on
the same side.
15. When assembling, bolts should be fastened using the plastic angle technique as follows.
1. Apply oil to the threads and matching areas.
2. Tighten the connecting rod bolt.
Tightening torque
Connecting rod bolt:
35 Nm (350 kg.cm, 26 lb. ft) +90°
CAUTION: After removing the connecting rod bolt, do not use it again.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
When using a new bolt, do not tighten the bolt more than 3 times.
16. Check the connecting rod side clearance.
Connecting rod side clearance
Standard: 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.)
Limit: 0.4 mm (0.0157 in.)
Fig. 110: Checking Connecting Rod Side Clearance

INSTALLATION
1. Install the upper baffle plate.

2. Install the oil screen.
3. Install the oil pan.
For additional information, refer to LUBRICATION SYSTEM.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
4. Install the cylinder head.
For additional information refer to CYLINDER HEAD.
5. Install the timing belt.
For additional information, refer to TIMING BELT.
CRANK SHAFT
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 111: Identifying Crankshaft Components

DISASSEMBLY
1. Remove the TIMING BELT train, front case, CYLINDER HEAD ASSEMBLY and oil pan.
2. Remove the rear plate and the rear oil seal.
3. Remove the connecting rod caps.
NOTE: Mark the main bearing caps to be able to reassemble in the original
position and direction.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
4. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order according to the
cap number.
INSPECTION
CRANKSHAFT
1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective parts.
2. Inspect the crankshaft journal and pin for out-of-round and taper.
Standard value
Crankshaft journal O.D:
63.982 ~ 64.00 mm (2.519 ~ 2.5197 in.)
Crankshaft pin O.D:
54.982 ~ 55.00 mm (2.165 ~ 2.1653 in.)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 112: Measuring Crankshaft Journals

MAIN BEARINGS AND CONNECTING ROD BEARINGS
Visually inspect each bearing for peeling, melting, seizure and improper contact. Replace any defective
bearings.
MEASURING OIL CLEARANCE
Check for oil clearance by measuring the outside diameter of the crankshaft journal and the inside diameter of
the bearing. The clearance can be obtained by calculating the difference between the measured outside
diameters.
Standard value
Oil clearance
Crankshaft main bearing:
0.022 ~ 0.040 mm (0.0009 ~ 0.0016 in.)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Connecting ~ rod bearing:
0.026 ~ 0.044 mm (0.001 ~ 0.0017 in.)
Fig. 113: Measuring Main Bearing Inside Diameter

PLASTIGAUGE METHOD
Plastigauge may be used to measure the clearance.
1. Remove oil, grease and any other dirt from the bearings and journals.
2. Cut the plastigauge the same length as the width of the bearing and place it in parallel with the journal,
avoiding the oil holes.
3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation,
do not turn the crankshaft. Remove the caps. Measure the width of the plastigauge at the widest part by
using the scale printed on the gauge package.
If the clearance exceeds the service limit, the bearing should be replaced or an undersize bearing should
be used. When installing a new crankshaft, be sure to use standard size bearings.
If the standard clearance can not be obtained even after replacing the bearing, the journal and pin should
be ground to the undersize and a bearing of the corresponding size should be installed.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 114: Using Plastigauge To Determine Main Bearing Clearance

OIL SEAL
Check the front and rear oil seals for damage or worn surfaces. Replace any seat that is defective.
DRIVE PLATE (A/T)
Replace distorted, damaged, or cracked drive plates.
REASSEMBLY
MAIN BEARING
1. Install a grooved main bearing (upper bearing) on the cylinder block side.
2. Install a grooveless main bearing (lower bearing) on the main bearing cap side.
3. Install the crankshaft. Apply engine oil to journal and pin.
4. Install the bearing caps with the arrow mark directed toward the front of the engine. Cap number must be
correct.
5. Tighten the cap bolts to the specified torque.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Tightening torque
Main bearing cap bolts:
90 ~ 100 Nm (900 ~ 1000 kg.cm, 65 ~ 72 lb. ft)
Fig. 115: Identifying Lower & Upper Main Bearings

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 116: Identifying Main Bearing Cap Tightening Sequence

6. Cap bolts should be tightened evenly in stages 4 to 5 increments before they are tightened to the specified
torque.
7. Make certain that crankshaft turns freely and check the end play of the crankshaft.
Crankshaft end play
Standard: 0.050 ~ 0.250 mm (0.002 ~ 0.0098 in.)
Limit: 0.35 mm (0.014 in.)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 117: Measuring Crankshaft End Play

8. Using special tool (09231-33000), install the rear oil seal in oil seal case.
9. Apply sealant to the area shown in the illustration. Install the oil seal case in the cylinder block.
Tightening torque
Oil seal case bolt:
10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 118: Identifying Oil Seal Installer

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 119: Identifying Sealing Agent Coating Location

10. Tighten the rear plate to the specified torque.
Tightening torque
Rear plate: 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb. ft)
11. Tighten the drive plate and the adapter plate (A/T).
Tightening torque
Drive plate and adapter plate bolt:
73 ~ 77 Nm (730 ~ 770 kg.cm, 53 ~ 56 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 120: Identifying Drive Plate, Adaptor Plate & Bolts

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
LUBRICATION SYSTEM
OIL PUMP
COMPONENTS
Fig. 121: Identifying Lubrication System Components

DISASSEMBLY
1. Remove the oil pressure switch, using 24 mm deep socket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 122: Removing Oil Pressure Switch

NOTE: Since a sealant is used on the threaded area, be careful not to damage the
oil pressure switch.
2. Remove the oil filter and the oil pan.

3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove the oil filter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump case.
6. Remove the oil pump case.
INSPECTION
OIL PUMP
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
1. Visually check the parts of the oil pump case for cracks and damage.
2. Assemble the rotor on the oil pump and then check the clearance with a thickness gauge.
Oil pump side clearance
Standard value
Body clearance:
0.100 ~ 0.181 mm (0.0039 ~ 0.0071 in.)
Side clearance:
0.040 ~ 0.095 mm (0.0016 ~ 0.0037 in.)
Oil pump Tip clearance:
0.06 ~ 0.18 mm (0.0024 ~ 0.0071 in.)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 123: Identifying Oil Pump Side & Body Clearances

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 124: Measuring Oil Pump Clearance

RELIEF PLUNGER AND SPRING
1. Check the relief plunger for smooth operation.

2. Check the relief spring for deformation or breaks.
OIL FILTER BRACKET
1. Make sure that there is no damage on the surface that mates with the oil filter.
2. Check the oil filter bracket for oil leaks or cracks.
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.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 125: Checking Oil Pressure Switch Continuity (Static)

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kpa (7 psi) vacuum is applied through the oil hole, the switch is
operating properly.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Check for air leakage. If air leaks, the diaphragm is broken Replace it.
Fig. 126: Checking Oil Pressure Switch Continuity (Using Fine Wire)
Operation Pressure
Oil pressure switch:
80 kpa (0.8 kg/cm2 , 11.4 psi) or more @ 700 rpm
REASSEMBLY
1. Install the oil pump case with the gasket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Tightening torque
Oil pump case bolt:
15 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 14 lb. ft)
Oil pump cover screw:
8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb. ft)
Fig. 127: Identifying Oil Pump

2. Install the oil seal into the oil pump case as tightly as possible, using the special tool (09214-33000).
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 128: Installing Oil Seal Into Oil Pump Case

3. Install the relief plunger and spring, and tighten the oil relief valve plug to the specified torque.
Tightening torque
Oil relief valve plug:
40 ~ 50 Nm (400 ~ 500 kg.cm, 29 ~ 36 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 129: Installing Relief Valve & Spring

4. Install the oil screen and a new gasket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Tightening torque
Oil screen bolt:
15 ~ 22 Nm (150 ~ 220 kg.cm, 11 ~ 15 lb. ft)
5. Clean the gasket surfaces of the cylinder block and the oil pan.
6. Apply sealant to the groove of the oil pan flange.
NOTE: 1. Make the first cut approx. 4 mm from the end of the nozzle furnished
with the sealant. After application of the sealant, do not exceed 15
minutes before installing the oil pan.
2. Make sure that the sealant doesn't enter the inside of the oil pan.
7. Install the oil pan and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt
*: 5 ~ 7 Nm (50 ~ 70 kg.cm, 4 ~ 5 lb. ft)
**: 5 ~ 7 Nm (50 ~ 70 kg.cm, 4 ~ 5 lb. ft)
***: 30 ~ 42 Nm (300 ~ 420 kg.cm, 22 ~ 30 lb. ft)
T/M tightening bolt (4EA):
10 ~ 12 Nm (100 ~ 120 kg.cm, 7.2 ~ 9 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 130: Upper Oil Pan Sealant Location & Individual Bolt Torque Identification
8. Tighten the oil pan bolts as shown in the illustration.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 131: Upper Oil Pan Bolt Tightening Sequence

9. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant: Three bond No. 1104E or equivalent
NOTE: Do not torque the oil pressure switch too much.
Tightening torque
Oil pressure switch:
8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb. ft)
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 132: Installing Oil Pressure Switch

10. Tighten the lower oil pan bolts as shown in figure.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 133: Lower Oil Pan Tightening Sequence

INTAKE AND EXHAUST SYSTEM

EXHAUST MANIFOLD
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 134: Identifying Exhaust Manifold Components

REMOVAL
1. Remove the front muffler.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 135: Removing Front Muffler (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 136: Removing Front Muffler (2 Of 2)

2. Remove the heat protector.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 137: Removing Heat Protector

3. Remove the exhaust manifold.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 138: Removing Exhaust Manifold

4. Remove the exhaust manifold gasket.
INSPECTION
1. Check for damage or cracks.

2. Using a straight edge and feeler gauge, check for distortion on the cylinder head matching surface.
Standard value: 0.15 mm (0.006 in.) or less
Service limit: 0.3 mm (0.012 in.) or less
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 139: Checking Exhaust Manifold For Warpage

3. Check the exhaust manifold for damage and cracks.
INSTALLATION
1. Install the exhaust manifold with gasket.
Tightening torque
Exhaust manifold:
40 ~ 45 Nm (400 ~ 450 kg.cm, 29 ~ 33 lb. ft)
NOTE: Do not re-use an exhaust manifold gasket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 140: Installing Exhaust Manifold

2. Install the heat protector.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 141: Installing Exhaust Manifold Heat Protector

3. Install the front muffler.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 142: Installing Front Muffler (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 143: Installing Front Muffler (2 Of 2)

INTAKE MANIFOLD
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 144: Identifying Intake Manifold Components

REMOVAL
1. Remove the air intake hose connected to the throttle body.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 145: Removing Throttle Body Air Intake Hose

2. Remove the engine coolant hose and throttle body.

3. Remove the P.C.V. hose and brake booster vacuum hoses.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 146: Removing PCV & Brake Booster Vacuum Hoses

4. Disconnect the vacuum hose connections.

5. Remove the surge tank stay.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 147: Removing Surge Tank Stay

6. Remove the surge tank.

7. Remove the surge tank and gasket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 148: Removing Surge Tank Gasket

8. Disconnect the fuel injector harness connector.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 149: Disconnecting Fuel Injector Harness Connectors

9. Remove the delivery pipe with the fuel injector and the pressure regulator.
NOTE: When the delivery pipe is removed, be careful not to drop an injector.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 150: Removing Fuel Delivery Pipe With Fuel Injectors

10. Disconnect the wiring harness of the coolant sensor assembly.
INSPECTION
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage, cracking or restriction of the vacuum outlet port,
water or gas passages.
2. Check for distortion on the surface using a straight edge and feeler gauge.
Standard value: 0.15 mm (0.006 in.) or less
Service limit: 0.2 mm (0.0078 in.)
INSTALLATION
Install the intake manifold and delivery pipe reversing the order of the removal procedure.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Tightening torque
Intake manifold:
12 ~ 15 Nm (120 ~ 150 kg.cm, 9 ~ 11 lb. ft)
Surge tank stay:
15 ~ 20 Nm (150 ~ 200 kg.cm, 11 ~ 14 lb. ft)
Fig. 151: Intake Manifold Tightening Sequence

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 152: Installing Surge Tank Stay

MUFFLER
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 153: Muffler/Exhaust System Components

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
REMOVAL
REAR MUFFLER
CAUTION: Before removing or inspecting the exhaust system, ensure that the
exhaust system is cool.
1. Disconnect the main muffler from the center exhaust pipe.
Fig. 154: Disconnecting Main Muffler From Center Exhaust Pipe

2. Remove the rubber hangers and the rear muffler.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 155: Removing Rubber Hangers & Rear Muffler (1 Of 2)

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 156: Removing Rubber Hangers & Rear Muffler (2 Of 2)

FRONT EXHAUST PIPE (INCLUDING CATALYTIC CONVERTER)
1. Remove the front exhaust pipe from the center exhaust pipe.
2. Remove the front exhaust pipe bolt and the exhaust manifold pipe mounting nuts.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 157: Removing Front Exhaust Pipe Bolt & Exhaust Manifold Pipe Mounting Nuts
3. Remove the front muffler bolts and nuts.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 158: Removing Front Exhaust Pipe Hangers

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 159: Removing Front Muffler Bolts & Nuts

INSPECTION
1. Check the mufflers and pipes for leaks, corrosion and damage.
2. Check the rubber hangers for deterioration and cracks.
INSTALLATION
1. Temporarily install the front muffler, the catalytic converter assembly and the rear muffler in this order.
2. Install the rubber hangers so that they hang equally left and right.
3. Tighten the parts securely and then confirm that there is no interference with any components.
Tightening torque
30 ~ 40 Nm (300 ~ 400 kg.cm, 22 ~ 29.5 lb. ft)
AIR CLEANER (ACL)
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 160: Identifying Air Cleaner Components

REMOVAL
1. Disconnect the air flow sensor connector.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 161: Disconnecting Airflow Sensor Connector

2. Remove the air intake hose and air duct connected to the air cleaner.
3. Remove the three bolts attaching the air cleaner mounting brackets.
4. Detach the air cleaner.
5. Remove the air flow sensor from the air intake hose.
CAUTION: Do not pull on the air flow sensor wires.
INSPECTION
1. Check the air intake hose, air cleaner cover for damage.
2. Check the air duct for damage.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 162: Inspecting Air Cleaner Assembly For Damage

3. Check the air cleaner element for restriction, contamination or damage.
If the element is slightly restricted, remove dust and debris by blowing compressed air from the inside of
the element. Replace the element it cannot be cleaned.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 163: Cleaning Air Filter Element

INSTALLATION
Install the air cleaner assembly following the reverse order of removal.
ENGINE BLOCK
ENGINE BLOCK
REMOVAL
Remove the timing belt, cylinder head assembly, drive plate, transaxle mounting plate, oil pan and oil pump
case.
INSPECTION
CYLINDER BLOCK
1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Replace the block if defective.

2. Measure the cylinder bore with a cylinder gauge at the three levels indicated, in the directions A and B.
Level 1: No. 1 piston ring position at TDC
Level 2: Center of cylinder
Level 3: Bottom of cylinder
Fig. 164: Measuring Cylinder Bore

3. If the cylinder bores show more than the specified out-of-round or taper, or if the cylinder walls are badly
scuffed or scored, the cylinder block should be re-bored and honed. New oversize pistons and rings
should be installed.
Standard value
Cylinder bore: 93 ~ 93.03 mm (3.661 ~ 3.6625 in.)
Out-of-round and taper of cylinder bore:
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Max. 0.02 mm (0.0008 in.)
4. If a ridge exists at the top of the cylinder, cut it off with a ridge reamer.
5. Oversize pistons are available in four sizes.
Piston service size and mark mm (in.)
0.25 (0.010) O.S.: 0.25
0.50 (0.020) O.S.: 0.50
6. To re-bore the cylinder bore to the oversize, maintain the specified clearance between the oversize piston
and the bore and make sure that all used pistons are the same oversize. The standard measurement of the
piston outside diameter is taken at a level of 12 mm (0.47 in.) above the bottom of the piston skirt and
across the thrust faces.
Piston - to - cylinder clearance:
0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
Fig. 165: Identifying Piston Measuring Location

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
7. Check for damage or cracks in the cylinders.

8. Check the top surface of the cylinder block for flatness. If the top surface exceeds the limit, grind to the
minimum limit or replace.
Standard value
Flatness of gasket surface:
Max. 0.03 mm (0.0012 in.)
Service limit
Flatness of gasket surface: 0.05 mm (0.0020 in.)
CAUTION: When the cylinder head is assembled, grinding less than 0.2 mm
(0.008 in.) is permissible.
Fig. 166: Checking Cylinder Block Top Surface Flatness

2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
BORING CYLINDER
1. Oversize pistons should be selected according to the largest bore cylinder.
Fig. 167: Oversize Piston Identification Table

NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.
New bore size = Piston O.D + 0.03 to 0.05 mm (0.0012 to 0.0020 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard: 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)
NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.
INSTALLATION
Install the following parts.
1. Crankshaft
2. Drive plate
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
3. Piston
4. Cylinder head
5. Oil pump case
6. Timing belt
ENGINE MOUNTS
COMPONENTS
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 168: Identifying Engine Mount Components

REMOVAL
Attach a cable or chain to the engine hooks, and then lift enough so that there is no pressure on the insulators.
ENGINE MOUNTING
1. Remove the engine mount bracket bolts and nut.
Fig. 169: Removing Engine Mount Bracket Bolt & Nut

2. Remove the engine mount bracket from the engine.
TRANSAXLE MOUNTING
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
1. Remove the air cleaner. For additional information refer to AIR CLEANER (ACL).
2. Remove the transaxle mounting bolt.
3. Remove the transaxle bracket.
Fig. 170: Removing Transaxle Bracket

FRONT ROLL STOPPER
1. Remove the transaxle mounting bolt.

2. Remove the transaxle bracket.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 171: Removing Front Roll Stop

REAR ROLL STOPPER
1. Remove the bolt from the rear roll stopper.

2. Remove the rear roll stopper from the sub - frame.
2004 Hyundai XG350
2003-05 ENGINES 3.5L V6 - XG350
Fig. 172: Removing Rear Roll Stop


XG350 2003 2005 3.5L

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2004 Hyundai XG350

2003-05 ENGINES 3.5L V6 - XG350

General Engine Specifications

viernes, 19 de febrero de 2021 07:58:45

Intake Max. 0.10 mm (0.0039 in.) 0.10 mm

Tropical area: 40%

Other area: 50%

Engine coolant: Ethylene glycol base for aluminum radiator

Fig. 1: Identifying Engine Coolant Temperature Sensor Sealant

Outer 14-15 (19-20)

Rear Roll Stopper Insulator Bolt & Nut 37-41 (50-65)

Water Outlet Fitting Bolt 13-15 (17-20)

INCH Lbs. (N.m)

(2) Tighten to 89-106 INCH Lbs. (10-12).

CHECKING ENGINE OIL

1. Position a vehicle on a level surface.

NOTE: When refilling, use the proper grade of engine oil.

Fig. 2: Identifying Engine Oil Operating Range On Engine Oil Dipstick

SELECTION OF ENGINE OIL

Recommended API classification: SH OR ABOVE [For EC.]

Recommended SAE viscosity grades:

Fig. 3: Identifying Recommended SAE Oil Viscosity Grades

1. Satisfy the requirements of the API classification.

CHANGE ENGINE OIL

1. Run the engine until if reaches normal operating temperature.

Drain the engine oil.

4. Tighten the drain plug to the specified torque.

Oil pan drain plug:

35 ~ 45 Nm (350 ~ 450 kg.cm, 25 ~ 33 lb. ft)

Fig. 4: Identifying Engine Oil Drain Plug & Seal

Drain and refill

6. Install the oil filler cap.

7. Start and run the engine.

REPLACEMENT OIL FILTER

Fig. 5: Identifying Engine Oil Filter Part Number Location

PROCEDURE FOR REPLACING OIL FILTER

1. Use a filter wrench to remove the oil filter.

Fig. 6: Locating Engine Oil Filter

Oil filter: 12 ~ 16 Nm (120 ~ 160 kg.cm, 8.7 ~ 11.6 lb. ft)

Fig. 7: Identifying & Lubricating Engine Oil Filter Seal

CHECKING COOLANT LEAK CHECK

1. Loosen the radiator cap.

4. If there is leakage, repair or replace with the appropriate part.

Fig. 8: Pressure Testing Cooling System

RADIATOR CAP PRESSURE TEST

1. Use an adapter to attach the cap to the tester.

Main valve opening pressure:

Main valve closing pressure:

83.4 kPa (0.85 kg/cm2 , 12.1 psi)

3. Check that the pressure level is maintained at or above the limit.

material on the cap seal will cause an incorrect reading.

Fig. 9: Pressure Testing Radiator Pressure Cap

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.

Fig. 10: Measuring Coolant Specific Gravity

RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

CAUTION: If the concentration of the coolant is below 30%, its anti-corrosion

Fig. 12: Identifying Recommended Coolant Mixing Ratios

CHECKING COMPRESSION PRESSURE