Hyundai Coupes/Sedans 1994-1998 Repair Guide

Camshaft and Lash Adjusters

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REMOVAL & INSTALLATION



1.5L (VIN K) SOHC, 1.5L (VIN E) and 1.5L (VIN J) Engines

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: The camshaft sprocket pin should protrude from the camshaft as illustrated-1.5L (VIN K) SOHC, 1.5L (VIN E) and 1.5L (VIN J) engines



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Fig. Fig. 2: The rear cylinder head cover must be removed to slide the camshaft from the cylinder head. The camshaft thrust case tightening bolt can also be seen in this illustration-1.5L (VIN J) engine



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Fig. Fig. 3: Ensure the camshaft is installed with the threaded hole in the top of the thrust case straight upward-1.5L (VIN J) engine



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Fig. Fig. 4: Use special tool (PN 09221-21000) or equivalent, drive a new front camshaft oil seal into the clearance between the cam and head, making sure the seal seats fully-1.5L (VIN K) SOHC, 1.5L (VIN E) and 1.5L (VIN J) engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. 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.
  6.  
  7. Remove the timing belt from the camshaft sprocket
  8.  

The timing belt may be left engaged with the crankshaft sprocket and tensioner.

  1. Remove the camshaft sprocket.
  2.  
  3. Remove the rocker cover.
  4.  
  5. Remove the rocker shaft assembly.
  6.  
  7. Remove the cylinder head rear cover (distributorless ignition) or distributor (distributor ignition).
  8.  

On distributorless ignition equipped engines, a cylinder head rear cover is used to block off the space formerly occupied by the distributor.

  1. Remove the camshaft thrust case tightening bolt.
  2.  
  3. Carefully, slide the camshaft out of the head, being careful that the cam lobes do not strike the bearing bores in the head.
  4.  

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 securely.
  8.  
  9. Install the cylinder head rear cover (distributorless ignition) with a new gasket. Tighten bolts to 6-7 ft. lbs. (8-10 Nm). Install the distributor (distributor ignition).
  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, making sure the seal seats fully.
  14.  
  15. Install the rocker shaft assembly.
  16.  
  17. Install the camshaft sprocket and torque the bolt to 47-54 ft. lbs. (64-74 Nm).
  18.  
  19. Install and tension the timing belt.
  20.  
  21. Install the timing belt covers
  22.  
  23. Temporarily adjust the valve clearance to specification with the engine cold.
  24.  
  25. Install the rocker cover.
  26.  
  27. Start the engine and allow it to reach operating temperature. Check for leaks.
  28.  
  29. Readjust the valve clearance with the engine warm.
  30.  

1.5L (VIN K) DOHC, 2.0L (VIN F) and 1996-98 1.8L (VIN M) Engines

See Figures 5, 6, 7, 8, 9 and 10



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Fig. Fig. 5: Camshaft assembly components-1.5L (VIN K) DOHC, 2.0L (VIN F) and 1996-98 1.8L (VIN M) engines



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Fig. Fig. 6: 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 (VIN K) DOHC, 2.0L (VIN F) and 1996-98 1.8L (VIN M) engines



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Fig. Fig. 7: The camshaft bearing caps are arranged on the cylinder head as illustrated-1.5L (VIN K) DOHC, 2.0L (VIN F) and 1996-98 1.8L (VIN M) engines



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Fig. Fig. 8: Using special tool (PN 09221-21000) or equivalent, install a new oil seal-1.5L (VIN K) DOHC, 2.0L (VIN F) and 1996-98 1.8L (VIN M) engines



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Fig. Fig. 9: Align the timing chain and camshaft sprockets as illustrated-1.5L (VIN K) DOHC engine



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Fig. Fig. 10: Align the timing chain and camshaft sprockets as illustrated-2.0L (VIN F) and 1996-98 1.8L (VIN M) engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. Remove the timing belt tensioner and idler.
  6.  
  7. Remove the timing belt from the camshaft sprocket.
  8.  

The timing belt may be left engaged with the crankshaft sprocket and tensioner.

  1. Remove the camshaft sprocket.
  2.  
  3. Remove the rocker cover.
  4.  
  5. Remove the camshaft bearing caps and timing chain.
  6.  
  7. Remove the camshaft from the cylinder head, being careful that the cam lobes do not strike the bearing bores in the head.
  8.  
  9. Remove the hydraulic lash adjusters.
  10.  

To install:
  1. Install the hydraulic lash adjusters.
  2.  
  3. Align the camshaft timing chain with the intake and exhaust camshaft sprockets as illustrated.
  4.  
  5. Lubricate all journal and thrust surfaces with clean engine oil.
  6.  
  7. Carefully insert the camshaft into the cylinder head.
  8.  
  9. Install the bearing caps and tighten to 9-10 ft. lbs. (12-14 Nm) in several stages. Start from the center cap and work outward to the end of the cylinder head.
  10.  

The 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. Using special tool (PN 09221-21000) or equivalent, install a new oil seal.
  2.  
  3. Install the camshaft sprocket and torque the bolt to 60-74 ft. lbs. (80-100 Nm).
  4.  
  5. Install and tension the timing belt.
  6.  
  7. Install the timing belt covers
  8.  
  9. Install the rocker cover.
  10.  
  11. Start the engine and allow it to reach operating temperature. Check for leaks.
  12.  

1.6L (VIN R), 1.8L (VIN M) and 2.0L (VIN P) Engines

See Figures 11, 12, 13, 14, 15, 16 and 17



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Fig. Fig. 11: Camshaft and rocker arm assembly components-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 12: The intake camshaft can be identified by the slits on its rear end. The exhaust camshaft does not have these slits-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 13: The camshaft bearing caps are identified by a letter indicating intake or exhaust and a number-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 14: Ensure the camshaft dowel pins are located at the 12 o-clock position-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 15: Tighten the camshaft bearing caps in the sequence specified-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 16: Lubricate the oil seal and install using special tool (PN 09221-21100) or equivalent-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 17: Install the crankshaft position sensor after aligning the notch with the punch mark-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines

  1. Disconnect battery negative cable.
  2.  
  3. Remove the timing belt cover.
  4.  
  5. Remove the rocker cover.
  6.  

Remove the crankshaft position sensor.

  1. Loosen the bearing cap bolts in 2-3 steps.
  2.  
  3. Label and remove all camshaft bearing caps.
  4.  

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.  

The hydraulic lash adjusters can be removed without disassembling the cylinder head by using special tool (PN 09246-34000), or equivalent.

  1. Remove the rocker arms and lash adjusters.
  2.  

To install:
  1. Lubricate the components with heavy engine oil.
  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.

  1. Install the camshafts.
  2.  
  3. Install the bearing caps. Ensure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Tighten in sequence using 2 or 3 steps to 14-15 ft. lbs. (19-21 Nm).
  4.  

Number 2 and 5 caps are of the same shape. Check the markings on the caps to identify the cap number and intake/exhaust symbol. OnlyL(intake) orR(exhaust) is stamped on No. 1 bearing cap.

  1. Lubricate the oil seal and install using special tool (PN 09221-21100) or equivalent.
  2.  

Install the camshaft sprockets and tighten to 58-72 ft. lbs. (80-100 Nm).

  1. Install the rocker covers.
  2.  
  3. Locate the pin on the sprocket side of the intake camshaft at the 12 o-clock position.
  4.  
  5. Align the punch mark on the crank angle sensor housing with the notch in the plate.
  6.  
  7. Install the crankshaft position sensor.
  8.  
  9. Install and tension the timing belt.
  10.  
  11. Install the timing belt covers.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  16.  

3.0L (VIN T) Engine

See Figures 18, 19, 20 and 21



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Fig. Fig. 18: Camshaft and rocker arm assembly components-3.0L (VIN T) engine



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Fig. Fig. 19: Before removing the rocker arm assemblies, use the lash adjuster retaining clips (PN 09246-32000) or equivalent to retain the lash adjusters-3.0L (VIN T) engine



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Fig. Fig. 20: Install the rocker arm assemblies with the arrows as indicated. Place sealer at the corners-3.0L (VIN T) engine



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Fig. Fig. 21: Lubricate the oil seal and install using special tool (PN 09221-33000) or equivalent-3.0L (VIN T) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Rotate the engine until the No. 1 cylinder is at TDC on the compression stroke and the timing marks on the camshaft sprockets align.
  6.  
  7. Remove the timing belts.
  8.  
  9. Remove the rocker covers.
  10.  
  11. Install auto lash adjuster retainer tools (PN 09246-32000) or equivalent on the rocker arms.
  12.  
  13. If removing the right side (front) camshaft, remove the distributor extension.
  14.  
  15. Remove the rocker arm and shaft assembly.
  16.  
  17. Remove the camshaft from the cylinder head.
  18.  

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 rocker arm and shaft assemblies. Apply sealer (Threebond No. 1324 or equivalent) at the ends of the bearing caps and install the assembly. Tighten bolts to 14-15 ft. lbs. (19-21 Nm).
  4.  
  5. Lubricate the oil seal and install using special tool (PN 09221-33000) or equivalent.
  6.  
  7. Install the distributor extension, if removed.
  8.  
  9. Remove auto lash adjuster retainer tools.
  10.  
  11. Install the rocker covers.
  12.  
  13. Install and tension the timing belts.
  14.  
  15. Install the timing belt covers.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and allow it to reach operating temperature. Check for leaks.
  20.  

 
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