QuestionThank you so much for you advice. Can you please tell me what "tsb" stands for ? and am I able to get a copy of it?
Thanks again
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Followup To
Question -
I have a 1996 Hyundai Sonata GLE that has travelled 75000kms, It has always been serviced by our local Hyundai dealer at the recommended intervals, and anything that has been advised to be replaced has been done. I had the timing belt replaced by the Hyundai dealer 18 months ago as I was advised that it need to be done after 5 years of age. When this was done, I week later, the car was running very rough and making an awful noise, I took it back to the dealer, and apparently they had forgotten to tighten up 6 bolts somewhere in the engine. They assured me that there had been no residual damage to the engine but it never ran as quietly as before. Presently my car is in peices at the Hyundai dealer, as it was presenting in a similar manner to when the timing belt was replaced, that is no acceleration (specially up hill) a loud rattling noise and running extremely rough and cutting out all the time. Firstly I was told that it was due to me using normal unleaded fuel, but as the problem got worse, I could not even drive the car to the Hyundai dealer, it had to be delivered there on the back of a tow truck. When the dealer looked at the car and put it on the computer, it said that the fuel pump needed to be replaced. This was done, but when the car was put back together, it was still running rough. The dealer then advised me that the timing was out. He has advised me today that the Tension Pulley has to be replaced. My question (sorry for it being so long winded) is would the initial problem when the timing belt was replaced have weakened the tension pulley and would it be normal practice to replace the tension pulley at the time of replacing the timing belt ? Thank you so much for your help
Answer -
OK your problems are one fold. the tensioner should have been replaced when they did the belt there is a tsb about this an if the tech knew what he was doing he would have also dont the water pump saves on time only the cost of the pump im my thoughts this is one they should be doing for free the belt was never streched right an then it got to big an then caoused the problems, so there fore the problem is from inproper instalation,
AnswerI HOPE THIS HELPS IT IS ALOT TO READ BUT TELLS YOU EVERYTHING THAT SHOULD HAVE BEEN DONE.....
TSB (TECHNICAL SERVICE BULLETIN )
SERVICE MANUAL
Applies to: Sonata 1995-1997
GROUP
Engine Mechanical System Timing System
REPAIR
Auto Tensioner
Check the auto tensioner for leaks and replace as necessary.
Check the rod end for wear or damage and replace as necessary.
Measure the rod protrusion. If it is out of specification, replace the auto tensioner.
SPECIFICATION
Rod protrusion 12 mm (0.47 in.)
Using a vise soft jaw, push in the auto tensioner rod. If the rod can be easily retracted, replace the auto tensioner. You should feel a fair amount of resistance when pushing the rod in.
CAUTION
Clamp the auto tensioner in the vise so that it is level. Use soft jaws in the vise to avoid damaging the auto tensioner.
If the plug is at the bottom of the auto tensioner, insert a plain washer to prevent directly contacting the plug with the vise.
SERVICE MANUAL
Applies to: Sonata 1995-1997
GROUP
Engine Mechanical System Timing System
TIMING BELT
Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
When the engine is overhauled or belt tension adjusted, carefully check the belt. If any of the following flaws are evident, replace the belt.
Description
Flaw conditions
1. Hardened back surface
Back surface glossy. Non-elastic and so hard that when your fingernail is pressed into it, no mark is produced.
2. Cracked back surface rubber
3. Cracked or separating canvas
4. Badly worn teeth (initial stage)
5. Badly worn teeth (last stage)
Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced)
6. Cracked tooth bottom
7. Missing tooth
8. Side of belt badly worn
NOTE
NOTE Normal belt should have precisely cut sides as if cut by a sharp knife.
9. Side of belt cracked
SERVICE MANUAL
Applies to: Sonata 1995-1997
GROUP
Engine Mechanical System Timing System
DISASSEMBLY
Remove the crankshaft pulley, engine coolant pump pulley and drive belt.
Remove the timing belt cover.
Turn the crankshaft clockwise and align the timing marks to bring the No. 1 cylinder to compression top-dead-center position. At this time, the timing marks of the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto tensioner.
CAUTION
Rotate the crankshaft clockwise.
Remove the timing belt.
NOTE
If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before.
Remove the camshaft sprockets.
NOTE
Be careful not to damage the cylinder head with the wrench.
When the oil pump sprocket nut is removed, first remove the plug at the left side of the cylinder block and insert a screwdriver to keep the left counter balance shaft in position. Use a screwdriver with a shaft measuring 8 mm (0.3in.) in diameter which can be inserted being more than 60 mm (2.36 in.)
Remove the oil pump sprocket retaining nut and the oil pump sprocket.
Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand.
Next, remove tensioner "B" and timing belt "B."
CAUTION
After timing belt "B" has been removed, do not attempt to loosen the bolt while holding sprocket with pliers, etc.
Remove the crankshaft sprocket "B" from crankshaft.
SERVICE MANUAL
Applies to: Sonata 1995-1997
GROUP
Engine Mechanical System Timing System
INSPECTION
Sprockets
Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary.
Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary.
SERVICE MANUAL
Applies to: Sonata 1995-1997
GROUP
Engine Mechanical System Timing System
REASSEMBLY
Install crankshaft sprocket "B" into crankshaft.
CAUTION
Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.
Lightly apply engine oil to the outer surface of spacer, and then install spacer to the right counter balance shaft. Be sure to install in the direction shown in illustration.
Install counterbalance shaft sprocket onto right counterbalance shaft, then finger tighten flange bolt.
Align timing mark on each sprocket with corresponding timing mark on the front case.
When timing belt "B" is installed, make certain that tension side has no slack. Install tensioner "B" with center of pulley located on the left side of mounting bolt and with pulley flange directed toward front of engine. Align timing mark on the right counter balance shaft sprocket with the timing mark on the front case.
Lift tensioner "B" to tighten timing belt "B" so that its tension side will be pulled tight. In this condition, tighten bolt to secure tensioner "B". When bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtightened.
Check to ensure that timing marks are in alignment.
Check to ensure that when center of span on the tension side is depressed with index finger in direction of arrow, deflection of belt is within specification.
MEASUREMENT SPECIFICATION
Belt deflection 5-7mm 0.2-0.3 in
Install flange and crankshaft sprocket onto crankshaft. Be sure to install in the direction shown in illustration.
CAUTION
Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could result.
Insert screwdriver through plug hole in left side of cylinder block to keep shaft in position.
Install the oil pump sprocket, and tighten the nut to the specified torque.
Install the camshaft sprocket and tighten the bolt to the specified torque.
TORQUE SPECIFICATION
Camshaft sprocket 80-100 Nm kg·cm 56-72 lb·ft
Install the auto tensioner.
CAUTION
Leave the wire installed in the auto tensioner.
NOTE
If the auto tensioner rod is in its fully extended position, reset it as follows.
Clamp it in a vise with soft jaws in a level position. Apply a plain washer if there is a plug at the bottom of the auto tensioner.
Push in the rod slowly with the vise until the set hole "A" in the rod is aligned with set hole "B" in the cylinder.
Install the tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt, then finger tighten the center bolt.
CAUTION
Leave the wire installed in the auto tensioner.
Turn the two sprockets so that their dowel pins are on top. Then, align the timing marks facing each other with the top surface of the cylinder head.
NOTE
The same camshaft sprocket is used for the intake and exhaust camshafts and is provided with two timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the one on the left with the dowel pin hole on top.
Align the crankshaft sprocket timing marks.
Align the oil pump sprocket timing marks.
Install the timing belt around the tensioner pulley and crankshaft sprocket. Secure the timing belt onto the tensioner pulley with your left hand.
Pulling the belt with your right hand, install it around the oil pump sprocket.
Install the belt around the idler pulley.
Install it around the intake camshaft sprocket.
Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder head top surface [see illustration in step 15]. Then, pulling the belt with both hands, install it around the exhaust camshaft sprocket.
Gently raise the tensioner pulley as shown by the arrow, so that the belt does not sag. Temporarily tighten the center bolt.
After turning the crankshaft 1/4 turn counterclockwise, turn it clockwise to move the No. 1 cylinder to top dead center.
Loosen the center bolt, then, as shown in the illustration, attach the special tool and a torque wrench and apply a torque of 2.6-2.8 Nm (1.88-2.03 lb.ft.). If the body interferes with the special tool and the torque wrench, use a jack to slightly raise the engine assembly.
NOTE
Use a torque wrench measuring within a range of 0-3 Nm (0-2.2 lb.ft.).
Holding the tensioner pulley with the special tool and torque wrench, tighten the center bolt to specification. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool a bit more and remove the set wire attached to the auto tensioner.
Remove the special tool.
Rotate the crankshaft two complete turns clockwise and leave it for about 15 minutes. Then, measure the auto tensioner protrusion "A" (distance between the tensioner arm and auto tensioner body) to ensure that it is up to specification.
MEASUREMENT SPECIFICATION
Auto tensioner protrusion A: 3.8-4.5mm 0.15-0.18in
If it is out of specification, repeat steps 24 through 28 until the specified value is obtained.
NOTE
If the clearance "A" between the tensioner arm and the auto tensioner body cannot be measured (when the engine is mounted on the vehicle, for example), the following alternative method may be used.
Screw in the special tool until its end makes contact with the tensioner arm.
Screw in the special tool a bit more to retract the auto tensioner push rod while counting the number of turns the tool makes to bring the tensioner arm into contact with the auto tensioner body.
Make sure that the number of turns the special tool makes conforms to the standard value.
SPECIFICATION
Standard value: 2.5-3 turns
Install the rubber plug to the timing belt rear cover.
Install the timing belt lower cover and the timing belt upper cover.
