Hyundai Repair: Crankshaft timing mark, timing pointer, sensor plate


Question
I've replaced the waterpump & timing belt in my son's girlfriend's '96 Sonata, and now when I start it, it's making a nasty tapping sound. I'm sure I've timed it correctly, but the info I've seen on this site & at www.hmaservice.com all show a timing mark on the crankshaft sproket lining up with a pointer adjacent to the oil pump timing pointer. I belive that relates to models up to '95. There's no such pointer on mine. The only reference mark I can use is the pulley locating pin in the sproket. I haven't removed the 22mm bolt of the end of the shaft to check if the dowel is on the left, but I took particular notice where the pulley locating pin was before I removed the old belt (It was at 3 0'clock with the cam sproket timing marks facing each other & the oil pump mark was pointing to the timing pointer ok).
I've gone back and double checked the timing as I think it should be. I dropped a long shafted screwdriver down no 1 plug hole to find TDC, and lined up the cams and belt from there making sure that the cam sproket timing marks faced each other with the dowels facing up. When I put a socket on the crankshaft nut & manually turn the engine over, I don't feel any binding or pistons hitting valves and the cam timing marks are still where they should be.

The car had overheated before I replaced the pump, so I s'pose there's a possibility that that's damaged something, but I started the engine after that and don't remember hearing any nasty noises.

Any suggestions apart from the fact that I'm probably hitting valves against pistons!

Answer
Because of the way you describe setting up the camshafts, I'm going to presume you have the 2.0 four cylinder.

If this tapping started immediately after doing the timing belt, here's my thoughts as to possibilities:
1.  Either the crankshaft of camshaft sensor plate was bent or damaged and is hitting the sensor.
2.  The timing belt is too loose.  The easiest way to check this is to measure the extension of the hydraulic tensioner piston and compare with the shop manual value.
3.  One of the drive accessories is scraping something.  I seem to vaguely recall having this occur with the power steering pump pulley or the a/c idler pulley, but I also cannot think of anything you'd need to do that would change any of the positions enough for something to hit.

I cannot picture in my mind very well what the front case looked like on this engine, so I don't recall whether what you saw on www.hmaservice.com is correct.  I looked and saw that 1995-1997 used the same procedure, so I went to the 1998 (same engine and setup) for comparison, and the picture there looks identical.  I pulled out the book I have for 1997 Sonata, and the picture there does look different from what's on the website.  From what I see there, it looks like the crank sensor plate has a V cut in it that lines up with a mark on the front case at about 11 O'clock, not near the oil pump sprocket like the website shows.