Hyundai Repair: 1997 Hyundai Accent setting timing, timing belt tensioner, crankshaft pulley


Question
We had to replace the water pump, and in the course of that, accidentally turned the crankshaft pulley.  Now we have to re-time it, the first time we aligned the camshaft marks, and although the engine started and ran, but when I turned on the AC the engine stalled, and we couldn't get it started again.  We figured that it is out of time, and now when the mark on the crankshaft is aligned with the timing cover marks, the other marks don't align.

Answer
The dimple on the crankshaft sprocket lines up with a tit on the oil pump case.  If I recall correctly, it's about 20 to 30 degrees clockwise from straight up.  The small hole in the camshaft sprocket lines up with the dimple in the top of the camshaft bearing cap.  I presume you had to remove the timing belt tensioner assembly when replacing the water pump, so you'll want to make sure that the timing belt tensioner spring isn't out of position-- it should press against a detent on the front of the engine and an arm on the tensioner assembly.

To install the belt:
1.  Line up the sprockets.
2.  Loosen the pivot and clamp bolts on the tensioner assembly.
3.  Pry the tensioner away and tighten the clamp bolt to hold it there.
4.  Install the timing belt with it taught on the front side and slack on the rear side (the side that rides the tensioner pulley).
5.  Loosen the tensioner clamping bolt to allow the tensioner to apply tension to the timing belt.
6.  Reclamp the tensioner.
7.  Rotate the crankshaft 720 degrees clockwise until the marks are again lined up.  Turning clockwise makes sure *all* the slack is on the tensioner side.
8.  Loosen and reclamp the tensioner one more time.  
9.  Tighten the tensioner pivot bolt.

At this point, you may wish to install the crank pulley to hold the crank sprocket in place and see if the engine starts and runs normally.  (Don't let it run too long because your water pump and alternator won't be running.)  If it runs normally, take the pulley back off and reassemble everything.  If it misfires or won't start (and your timing marks are lined up), you've probably damaged at least some of your valves.