Hyundai Coupes/Sedans 1986-1993 Repair Guide

Camshaft

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REMOVAL & INSTALLATION



1468cc Engine

See Figures 1 through 5

  1. Disconnect the negative battery cable. Remove the rocker cover. Remove the timing belt cover. Remove the distributor.
  2.  



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Fig. Fig. 1: Removing the camshaft cover-1468cc engine



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Fig. Fig. 2: When removing the camshaft, use care not to damage the bearings-1468cc engine



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Fig. Fig. 3: Measuring the camshaft end-play-1468cc engine



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Fig. Fig. 4: Camshaft seal installation-1468cc engine



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Fig. Fig. 5: Camshaft thrust case alignment-1468cc engine

  1. Loosen the 2 bolts and move the timing belt tensioner toward the water pump as far as it will go, then retighten the timing belt tensioner adjusting bolt. Disengage the timing belt from the camshaft sprocket and unbolt and remove the sprocket. The timing belt may be left engaged with the crankshaft sprocket and tensioner.
  2.  
  3. Remove the rocker shaft assembly. Remove the small, square cover that sits directly behind the camshaft on the transaxle side of the head. Remove the camshaft thrust case tightening bolt that sits on the top of the head right near that cover.
  4.  
  5. Carefully, slide the camshaft out of the head through the hole in the transaxle side of the head, being careful that the cam lobes do not strike the bearing bores in the head.
  6.  

To install:
  1. Lubricate all journal and thrust surfaces with clean engine oil.
  2.  
  3. Carefully insert the camshaft into the engine. Make sure the camshaft goes in with the threaded hole in the top of the thrust case straight upward.
  4.  
  5. Align the bolt hole in the thrust case and the cylinder head surface.
  6.  
  7. Install the thrust case bolt and tighten firmly.
  8.  
  9. Install the rear cover with a new gasket and install and tighten the bolts to 5.8-7.2 ft. lbs. (8-10 Nm).
  10.  
  11. Coat the external surface of the front oil seal with engine oil.
  12.  
  13. Using special installer tool MD 998306-01 or equivalent, drive a new front camshaft oil seal into the clearance between the cam and head at the forward end, making sure the seal seats fully.
  14.  
  15. Install the camshaft sprocket and torque the bolt to 47-54 ft. lbs. (64-74 Nm).
  16.  
  17. Reconnect the timing belt, check the timing and adjust the belt tension.
  18.  
  19. Reinstall the rocker shaft assembly. Adjust the valves and install the rocker and timing belt covers.
  20.  

1495cc Engine

See Figures 6 and 7

  1. Disconnect the negative battery cable. Remove the rocker cover. Remove the air intake tube on turbocharged models. Remove the timing belt cover. Remove the distributor.
  2.  



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Fig. Fig. 6: Removing the camshaft from the cylinder head-1495cc engine



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Fig. Fig. 7: Installing the camshaft oil seal-1495cc engine

  1. Loosen the 2 bolts and move the timing belt tensioner toward the water pump as far as it will go, then retighten the timing belt tensioner adjusting bolt. Disengage the timing belt from the camshaft sprocket and unbolt and remove the sprocket. The timing belt may be left engaged with the crankshaft sprocket and tensioner.
  2.  
  3. Remove the rocker shaft assembly.
  4.  
  5. Remove the camshaft bearing caps, making sure to note the original location of each cap.
  6.  
  7. Remove the camshaft from the cylinder head.
  8.  

To install:
  1. Check the camshaft journals for wear, if the journals are worn or shown signs of damage, replace the camshaft.
  2.  
  3. Check each part of the camshaft bearings, if the bearings are excessively worn, replace the bearing cap or the cylinder head as needed.
  4.  
  5. Check the camshaft oil seal and replace it if needed.
  6.  
  7. Lubricate the camshaft journals with clean engine oil and install the camshaft into the cylinder head.
  8.  
  9. Install the camshaft bearing caps and tighten the bolts to 14-20 ft. lbs. (20-27 Nm). Tighten the camshaft bearing caps starting from the center and working outward to the end caps.
  10.  
  11. Install the rocker arm shaft assembly.
  12.  
  13. Install a new camshaft oil seal, using tool 09221-21000 or equivalent. Install the distributor.
  14.  
  15. Install the camshaft sprocket. Align the camshaft sprocket and the crankshaft sprocket timing marks and install the timing belt.
  16.  
  17. Adjust the valve clearance to the proper specification for a cold engine. Install the rocker cover, using a new gasket. Install the air intake tube on turbocharged models.
  18.  
  19. Install the timing belt cover and the accessory drive belts. Connect the negative battery cable. Run the engine to normal operating temperature, then recheck the valve clearance once the engine has been warmed, adjust it if needed.
  20.  

2351cc Engine

See Figures 8, 9 and 10

A special tool 09246-32000 (MD998443) or equivalent, is required to retain the automatic lash adjusters in this procedure.



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Fig. Fig. 8: Camshaft components-2351cc engine



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Fig. Fig. 9: Camshaft oil seal installation-2351cc engine



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Fig. Fig. 10: Camshaft sprocket installation-2351cc engine

  1. Remove the rocker cover and gasket and the timing belt cover.
  2.  
  3. Turn the crankshaft so the No. 1 piston is at TDC compression. At this point, the timing mark on the camshaft sprocket and the timing mark on the head to the left of the sprocket will be aligned.
  4.  
  5. Remove the timing belt and camshaft sprocket.
  6.  
  7. Remove the camshaft bearing cap bolts.
  8.  
  9. Install the automatic lash adjuster retainer tool 09246-32000 or equivalent, to keep the adjuster from falling out of the rocker arms.
  10.  
  11. Lift off the bearing caps and rocker arm assemblies.
  12.  
  13. Lift out the camshaft.
  14.  

Keep all parts in the order in which they were removed. None of the parts are interchangeable. The lash adjusters are filled with diesel fuel, which will spill out if they are inverted. If any diesel fuel is spilled, the adjusters must be bled.

To install:
  1. Check all parts for wear or damage. Replace any damaged or excessively worn part.
  2.  
  3. Coat the camshaft with clean engine oil and place it on the head.
  4.  
  5. Assemble all parts. Note the following:
    1. The rocker shafts are installed with the notches in the ends facing up.
    2.  
    3. The left rocker shaft is longer than the right.
    4.  
    5. The wave washers are installed on the left shaft.
    6.  
    7. Coat all parts with clean engine oil prior to assembly.
    8.  
    9. Insert the lash adjuster from under the rocker arm and install the special holding tool. If any of the diesel fuel is spilled, the adjuster must be bled.
    10.  
    11. Tighten the bearing cap bolts, working from the center towards the ends, to 15 ft. lbs. (20 Nm) in 3 progressions.
    12.  
    13. Check the operation of each lash adjuster by positioning the camshaft so the rocker arm bears on the low or round portion of the cam, pointed part of the cam facing straight down. Insert a thin steel wire, or tool MD998442 or equivalent, in the hole in the top of the rocker arm, over the lash adjuster and depress the check ball at the top of the adjuster. While holding the check ball depressed, move the arm up and down. Looseness should be felt. Full plunger stroke should be 2.2mm. If not, remove, clean and bleed the lash adjusters.
    14.  

  6.  

1596cc, 1796cc and 1997cc Engines

See Figures 11 through 16

  1. Relieve the fuel system pressure.
  2.  



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Fig. Fig. 11: Camshaft and rocker arms-1596cc, 1796cc and 1997cc engines

  1. Disconnect battery negative cable.
  2.  
  3. Disconnect the accelerator cable.
  4.  
  5. Remove the timing belt cover and timing belt.
  6.  
  7. Remove the center cover, breather and PCV hoses, and spark plug cables.
  8.  
  9. Remove the rocker cover, semi-circular packing, throttle body stay, crankshaft angle sensor, both camshaft sprockets, and oil seals.
  10.  
  11. Loosen the bearing cap bolts in 2-3 steps. Label and remove all camshaft bearing caps.
  12.  

If the bearing caps are difficult to remove, use a plastic hammer to gently tap the rear part of the camshaft.

  1. Remove the intake and exhaust camshafts.
  2.  
  3. Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging.
  4.  

To install:
  1. Lubricate the camshafts with heavy engine oil and position the camshafts on the cylinder head.
  2.  

Do not confuse the intake camshaft with the exhaust camshaft. The intake camshaft has a split on its rear end for driving the crank angle sensor.



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Fig. Fig. 12: Camshaft identification-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 13: Camshaft bearing cap identification marks-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 14: Check the position of the camshaft dowel pins-1596cc, 1796cc and 1997cc engines

  1. Make sure the dowel pin on both camshaft sprocket ends are located on the top.
  2.  



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Fig. Fig. 15: Camshaft bearing cap tightening sequence-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 16: Camshaft seal installation-1596cc, 1796cc and 1997cc engines

  1. Install the bearing caps. Tighten the caps in sequence and in 2 or 3 steps. No. 2 and 5 caps are of the same shape. Check the markings on the caps to identify the cap number and intake/exhaust symbol. Only L (intake) or R (exhaust) is stamped on No. 1 bearing cap. Also, make sure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Torque the retaining bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Apply a coating of engine oil to the oil seal. Using tool MD998307 or equivalent, press-fit the seal into the cylinder head.
  4.  
  5. Align the punch mark on the crank angle sensor housing with the notch in the plate. With the dowel pin on the sprocket side of the intake camshaft at top, install the crank angle sensor on the cylinder head.
  6.  

Do not position the crank angle sensor with the punch mark positioned opposite the notch; this position will result in incorrect fuel injection and ignition timing.

  1. Install the timing belt, valve cover and all related parts.
  2.  
  3. Connect the negative battery cable and check for leaks.
  4.  

2972cc Engine

See Figures 17, 18, 19 and 20

  1. Disconnect the negative battery cable. Remove the air cleaner assembly and valve covers.
  2.  



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Fig. Fig. 17: Camshafts and related components-2972cc engine



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Fig. Fig. 18: Camshaft oil seal installation-2972cc engine



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Fig. Fig. 19: Camshaft circular packing installation-2972cc engine



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Fig. Fig. 20: Camshaft sprocket removal and installation-2972cc engine

  1. Install auto lash adjuster retainer tools MD998443 or equivalent on the rocker arms.
  2.  
  3. If removing the right side (front) camshaft, remove the distributor extension.
  4.  
  5. Remove the camshaft bearing caps but do not remove the bolts from the caps.
  6.  
  7. Remove the rocker arms, rocker shafts and bearing caps, as an assembly.
  8.  
  9. Remove the camshaft from the cylinder head.
  10.  
  11. Inspect the bearing journals on the camshaft, cylinder head and bearing caps.
  12.  

To install:
  1. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head.
  2.  
  3. Align the camshaft bearing caps with the arrow mark depending on cylinder numbers and install in numerical order.
  4.  
  5. Apply sealer at the ends of the bearing caps and install the assembly.
  6.  
  7. Torque the rocker arm and shaft assembly bolts to 15 ft. lbs. (21 Nm).
  8.  
  9. Install the distributor extension, if removed.
  10.  
  11. Install the valve cover and all related parts. Torque the valve cover retaining bolts to 7 ft. lbs. (10 Nm).
  12.  
  13. Connect the negative battery cable and road test the vehicle.
  14.  

 
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