QuestionI have a 2004 Hyundai Sonata with a 2.4L 4 cylinder... I am in the process of replacing the Crank shaft positioning sensor... When I removed the timing belt, both cam pulley's rolled forward... How do I position the Cam shafts in conjunction with the crank shaft to be at Top Dead Center
AnswerYou'll need to line up the crankshaft, the oil pump/front balance shaft, and the camshaft sprockets.
The crankshaft sprocket has a dimple which lines up with a pointer on the oil pump case. The V cut into the crank sensor plate should also line up with this pointer.
The oil pump/front balance shaft sprocket also has a dimple which lines up with a pointer on the oil pump case. This sprocket does not turn 1:1 with the balance shaft, but rather 2:3. Line up the sprocket and turn it slightly away from the pointer. If it tends to return, this is the correct position. If it tends to continue turning in the same direction, you'll need to rotate the oil pump/front balance shaft sprocket 360 degrees.
Each of the camshafts has a mark which aligns with a pointer on the valve cover.
When installing the belt:
-- Remove the auto-tensioner, compress in a vise, and install a pin (or appropriately sized drill bit) to hold the plunger in.
-- Install the belt around the crank sprocket, wedging an appropriately sized socket or similar tool between the belt and the oil pump case lip to keep the belt in place.
-- Loop the belt around the oil pump/front balance shaft sprocket, taking up the slack and verifying proper alignment.
-- Install the belt on the exhaust camshaft, again taking up slack and verifying proper alignment. Hold in place with vice grips or spring-type paper clip.
-- Install the belt on the intake camshaft in the same manner as the exhaust camshaft.
-- Bolt the auto-tensioner in place and remove the pin.
