Hyundai Car 1999-05

Camshaft, Bearings & Lifters

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Intake manifold
     
    Breather hose and engine harness
     
    Power steering pulley
     
    A/C pulley
     
    Crankshaft pulley
     
    Idler pulley and tensioner pulley
     
    Timing belt cover and loosen the auto tensioner
     
    Timing belt
     
    Spark plug cables
     
    Rocker arm cover
     
    Camshaft sprockets
     
    Camshaft bearing caps
     
    Camshafts
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the camshaft and related components-XG 300 and XG 350


To install:

  1. Rotate the crankshaft so that the No. 1 cylinder is at the Top Dead Center (TDC) position.
  2.  
  3. Make certain that the rocker arm is installed properly on the lash adjuster and valve.
  4.  
  5. Install the camshaft dowel pin.
  6.  
  7. Install or connect the following:

    Hydraulic lash adjusters in their original locations
     
    Lash adjuster retaining clips
     
    Camshafts
     
    Rocker arm and shaft assemblies and torque the bearing cap bolts 14-15 ft. lbs. (19-21 Nm) starting from the center and working out
     

  8.  
  9. Remove the lash adjuster retaining clips.

    Camshaft sprockets and torque the bolts to 79 ft. lbs. (110 Nm)
     
    Rocker arm cover with a new gasket
     
    Spark plug cables
     
    Timing belt, cover and tensioner
     
    Idler pulley
     
    Tensioner pulley
     
    Crankshaft pulley
     
    A/C pulley
     
    Power steering pump pulley
     
    Breather hose and engine harness
     
    Intake manifold
     
    Engine cover
     
    Negative battery cable
     

  10.  


    Click image to see an enlarged view

    Fig. Install the camshaft dowel pin as shown-XG 300 and XG 350


1.5L DOHC, 1.6L DOHC, 1.8L, 2.0L And 2.4L Engines


Click image to see an enlarged view

Fig. Camshaft assembly components-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are identified with a letter and number stamp. The letter indicates either intake or exhaust and the number is sequential from the cylinder head end opposite the timing chain-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are arranged on the cylinder head as illustrated-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Align the timing chain and camshaft sprockets as illustrated-DOHC engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Valve cover
     
    Camshaft bearing caps and timing chain
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and timing chain and torque the bolts to 15 ft. lbs. (21 Nm) for 2.0L (VIN P) engines or to 10 ft. lbs. (14 Nm) for all others
     
    Valve cover
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the camshaft and rocker arm assembly components-Sonata 2.0L engines



    Click image to see an enlarged view

    Fig. Intake and exhaust camshaft identification-Sonata 2.0L engines



    Click image to see an enlarged view

    Fig. Bearing cap torque sequence-Sonata 2.0L engines

     

  2.  



Click image to see an enlarged view

Fig. Camshaft assembly components-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are identified with a letter and number stamp. The letter indicates either intake or exhaust and the number is sequential from the cylinder head end opposite the timing chain-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are arranged on the cylinder head as illustrated-1.5L DOHC, 1.8L and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Align the timing chain and camshaft sprockets as illustrated-DOHC engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Valve cover
     
    Camshaft bearing caps and timing chain
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and timing chain and torque the bolts to 15 ft. lbs. (21 Nm) for 2.0L (VIN P) engines or to 10 ft. lbs. (14 Nm) for all others
     
    Valve cover
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the camshaft and rocker arm assembly components-Sonata 2.0L engines



    Click image to see an enlarged view

    Fig. Intake and exhaust camshaft identification-Sonata 2.0L engines



    Click image to see an enlarged view

    Fig. Bearing cap torque sequence-Sonata 2.0L engines

     

  2.  

1.5L DOHC, 2.0L And 2.4L Engines


Click image to see an enlarged view

Fig. Camshaft assembly components-1.5L DOHC, and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are identified with a letter and number stamp. The letter indicates either intake or exhaust and the number is sequential from the cylinder head end opposite the timing chain -1.5L DOHC, and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. The camshaft bearing caps are arranged on the cylinder head as illustrated-1.5L DOHC, and Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Align the timing chain and camshaft sprockets as illustrated-DOHC engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Valve cover
     
    Camshaft bearing caps and timing chain
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  


NOTE
Keep all valvetrain components in order for assembly.

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and timing chain and torque the bolts to 15 ft. lbs. (21 Nm) for 2.0L (VIN P) engines or to 10 ft. lbs. (14 Nm) for all others
     
    Valve cover
     
    Distributor, if equipped
     
    Camshaft position sensor, if equipped
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  


    Click image to see an enlarged view

    Fig. Exploded view of the camshaft and rocker arm assembly components-Sonata with 2.0L engine



    Click image to see an enlarged view

    Fig. Intake and exhaust camshaft identification-Sonata with 2.0L engine



    Click image to see an enlarged view

    Fig. Bearing cap torque sequence-Sonata with 2.0L engine


1.5L SOHC Engines

NOTE
The hydraulic lash adjusters are housed in the rocker arms.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Ignition coil
     
    Valve cover
     
    Front cover
     
    Timing belt
     
    Camshaft timing belt sprocket
     
    Rocker arm and shaft assembly
     
    Camshaft bearing caps
     
    Camshaft
     

  4.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps
     
    Rocker arm and shaft assembly and torque the bolts evenly to 14-20 ft. lbs. (20-26 Nm)
     
    Camshaft timing belt sprocket and torque the bolt to 58-72 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Valve cover
     
    Ignition coil
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  


NOTE
The hydraulic lash adjusters are housed in the rocker arms.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Ignition coil
     
    Valve cover
     
    Front cover
     
    Timing belt
     
    Camshaft timing belt sprocket
     
    Rocker arm and shaft assembly
     
    Camshaft bearing caps
     
    Camshaft
     

  4.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps
     
    Rocker arm and shaft assembly and torque the bolts evenly to 14-20 ft. lbs. (20-26 Nm)
     
    Camshaft timing belt sprocket and torque the bolt to 58-72 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Valve cover
     
    Ignition coil
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  


NOTE
The hydraulic lash adjusters are housed in the rocker arms.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Ignition coil
     
    Valve cover
     
    Front cover
     
    Timing belt
     
    Camshaft timing belt sprocket
     
    Rocker arm and shaft assembly
     
    Camshaft bearing caps
     
    Camshaft
     

  4.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps
     
    Rocker arm and shaft assembly and torque the bolts evenly to 14-20 ft. lbs. (20-26 Nm)
     
    Camshaft timing belt sprocket and torque the bolt to 58-72 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Valve cover
     
    Ignition coil
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  

2.5L & 2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Camshaft Position Sensor (CMP)
     
    Valve cover
     
    Camshaft bearing caps
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  


NOTE
Keep all valvetrain components in order for assembly.

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and torque the bolts to 10 ft. lbs. (14 Nm)
     
    Valve cover
     
    CMP sensor
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Camshaft Position Sensor (CMP)
     
    Valve cover
     
    Camshaft bearing caps
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and torque the bolts to 10 ft. lbs. (14 Nm)
     
    Valve cover
     
    CMP sensor
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Camshaft sprocket
     
    Camshaft Position Sensor (CMP)
     
    Valve cover
     
    Camshaft bearing caps
     
    Intake and exhaust camshafts
     
    Hydraulic lash adjusters
     

  4.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Intake and exhaust camshafts with the secondary chain aligned as shown
     
    Camshaft bearing caps and torque the bolts to 10 ft. lbs. (14 Nm)
     
    Valve cover
     
    CMP sensor
     
    Camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm)
     
    Timing belt
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  

3.0L Engine


Click image to see an enlarged view

Fig. Exploded view of the camshaft and rocker arm assembly components-3.0L engine



Click image to see an enlarged view

Fig. Before removing the rocker arm assemblies, install lash adjuster retaining clips (PN 09246-32000)-3.0L engine



Click image to see an enlarged view

Fig. Install the rocker arm assemblies with the arrows as indicated. Place sealer at the corners-3.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for installation.



    Negative battery cable
     
    Accessory drive belts
     
    Power steering pump
     
    Engine mount and bracket
     
    Front cover
     
    Timing belt
     
    Camshaft sprockets
     
    Distributor
     
    Distributor adapter housing
     
    Valve covers
     

  4.  
  5. Install special holding clip (PN 09246 3200) on each rocker arm to hold the hydraulic lash adjusters in place.
  6.  
  7. Loosen the bearing cap bolts evenly and remove the rocker shaft assembly from the cylinder head with the bolts still in place.
  8.  
  9. Remove or disconnect the following:

    Lash adjuster retaining clips
     
    Hydraulic lash adjusters
     
    Camshafts
     

  10.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original locations
     
    Lash adjuster retaining clips
     
    Camshafts
     
    Rocker arm and shaft assemblies and torque the bearing cap bolts 14-15 ft. lbs. (19-21 Nm) starting from the center and working out
     

  2.  
  3. Remove the lash adjuster retaining clips.
  4.  
  5. Install or connect the following:

    Valve covers
     
    Distributor adapter housing
     
    Distributor
     
    Camshaft sprockets
     
    Timing belt
     
    Front cover
     
    Engine mount and bracket
     
    Power steering pump
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  

 
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