2004 Hyundai Sonata Timing & Counterbalance Shaft Belts Removal and Installation

Removal CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing. 1. Remove drive belts and drive pulleys from crankshaft and water pump. Remove timing belt covers. To align timing marks, rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing marks align with upper surface of rocker cover. Dowel pin of camshaft sprocket should be pointing upward. See Fig. 1 and Fig. 2 . 2. Remove timing belt auto tensioner. If reusing timing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Remove camshaft sprockets. 3. Remove plug at left side of block and insert a screwdriver to hold left counterbalance shaft in position. Screwdriver will have to be inserted at least 2.36" (60 mm). Remove oil pump sprocket nut and sprocket. See Fig. 2 . 4. Loosen right counterbalance shaft sprocket mounting bolt. Remove tensioner "B" and timing belt "B". See Fig. 2 . Remove crankshaft sprocket "B" from crankshaft.
Inspection 1. Check belt teeth for cracks, damage and oil contamination. Inspect sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Check sprockets and pulleys for wear, cracks or damage. Replace components if necessary. 2. Measure protrusion of auto tensioner rod. From end of housing, auto tensioner rod should extend .55" (14 mm) on Sonata or .57" (15 mm) on Santa Fe. Replace auto tensioner rod, if not within specification. Place tensioner in a soft-jawed vise, and test resistance of rod. If rod can be easily pushed in with light vise pressure, replace auto tensioner.
Installation 1. Install crankshaft sprocket "B" onto crankshaft. Ensure flange is properly positioned. Lightly oil outer surface of spacer, and then install spacer onto right counterbalance shaft, with rounded edge of spacer inward. 2. Install counterbalance shaft sprocket. Tighten flange bolt tightly by hand. Align timing marks on each sprocket and on front case. 3. When installing timing belt "B", ensure there is no slack in tension side. Install tensioner "B" in center of pulley of left side of mounting bolt, and in pulley flange toward front of engine. See Fig. 3 . Align timing mark of right counterbalance shaft sprocket with timing mark on front case. 4. To tighten timing belt "B", lift tensioner "B" so tension side is pulled tight. Tighten bolt to secure tensioner "B". DO NOT turn shaft, or belt will be over-tightened. 5. Ensure timing marks are aligned. Ensure center of span on tension side of timing belt "B" can be depressed by hand. Ensure belt deflection is .20-.28" (5-7 mm).

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