Hyundai Coupes/Sedans 1994-1998 Repair Guide

Rocker Arms and Shafts

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REMOVAL & INSTALLATION



See Figures 1 through 6



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Fig. Fig. 1: Loosen the rocker shaft bolts evenly to prevent bending the shaft, but do not remove them....



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Fig. Fig. 2: ....then remove the rocker shaft as an assembly



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Fig. Fig. 3: Rocker shaft assembly components and arrangement



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Fig. Fig. 4: Disassemble the rocker shaft by removing the shaft bolt....



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Fig. Fig. 5: ....and sliding the components off the shaft



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Fig. Fig. 6: Shaft springs may have different tensions and installed heights. Return them to their original positions

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

See Figures 7 and 8



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Fig. Fig. 7: Rocker assembly components and arrangement.Rockers marked "C" and "D" must be returned totheir original positions-1.5L (VIN J) engine



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Fig. Fig. 8: Rocker assembly components and arrangement.Rockers marked "A" and "B" must be returned to theiroriginal positions-1.5L (VIN E) and 1.5L (VIN K) engines

  1. Remove the rocker cover.
  2.  
  3. Loosen the rocker shaft bolts evenly and remove the rocker shaft assembly from the cylinder head with the bolts still in place.
  4.  
  5. Disassemble the rocker shaft by progressively removing each bolt and then the associated springs and rockers, keeping all parts in the exact order of disassembly.
  6.  

It is important to keep all parts in the exact order of removal. Two types of rocker arms are used, and "A" type and a "B" type. Do not mix them up.

To install:
  1. Inspect the components as follows:
    1. On engines with roller rockers, inspect the roller on the rocker arm. Replace any rockers where the rollers are dented, damaged or show evidence of seizure. Ensure the oil hole on the bottom of the rocker arm near the roller is not clogged.
    2.  
    3. On engines with standard rockers, inspect the rocker face contacting the cam lobe and the adjusting screw that contacts the valve stem for excess wear. If badly worn or damaged, replace the rocker.
    4.  
    5. Inspect the fit of the rockers on the shaft. Replace rockers or the shaft as necessary.
    6.  
    7. On engines with hydraulic lash adjusters, inspect the lash adjuster face that contacts the valve stem. Replace the lash adjuster if worn or damaged.
    8.  

  2.  
  3. Reassemble the rocker shaft making sure all components are installed in their original positions.
  4.  
  5. Install the rocker shaft on the cylinder head and tighten bolts evenly to 14-20 ft. lbs. (20-26 Nm).
  6.  
  7. Install the rocker cover using a new gasket.
  8.  
  9. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  10.  
  11. On 1.5L (VIN E) and 1.5L (VIN J) engines, adjust the valve lash.
  12.  

3.0L (VIN T) Engines

See Figures 9, 10, 11 and 12



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Fig. Fig. 9: Rocker assembly components and arrangement. Rockers marked "A" and "B" must be returned to their original positions-3.0L (VIN T) engine



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Fig. Fig. 10: Rocker assembly identification marks-3.0L (VIN T) engine



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Fig. Fig. 11: Install special holding clip (PN 09246 3200) on each rocker arm to prevent the hydraulic lash adjusters from falling out during servicing-3.0L (VIN T) engine



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Fig. Fig. 12: Insert bearing cap No. 1 so the notch on the end of the shaft faces in the direction shown. Ensure the oil groove faces downward and the oil port is located on the shaft "A" side-3.0L (VIN T) engine

The 3.0L (VIN T) engine is equipped with hydraulic lash adjusters. To prevent the lash adjusters from falling out during removal of the rocker arms, special holding clips (PN 09426 32000) are used to hold the adjusters in place. The lash adjuster is filled with diesel fuel. Store the adjusters in the upright position or cover with masking tape to prevent the diesel fuel from spilling out. If the fuel spills out the adjusters must be bled.

  1. Remove the rocker cover.
  2.  
  3. Install special holding clip (PN 09246 3200) on each rocker arm to prevent the hydraulic lash adjusters from falling out during removal (and installation).
  4.  
  5. Loosen the bearing cap bolts evenly and remove the rocker shaft assembly from the cylinder head with the bolts still in place.
  6.  
  7. Disassemble the rocker shaft by removing the bearing cap bolts and sliding the rocker shafts from the bearing caps.
  8.  

It is important to keep all parts in the exact order of removal. Two types of rocker arms are used, and "A" type and a "B" type. Do not mix them up.

To install:
  1. Inspect the components as follows:
    1. On engines with roller rockers, inspect the roller on the rocker arm. Roller should not bind or have excessive play. If eccentric rotation or backlash is evident, or if rollers are dented, damaged or show evidence of seizure, replace the rocker. Ensure the oil hole on the bottom of the rocker arm near the roller is not clogged.
    2.  
    3. On engines with standard rockers, inspect the rocker face contacting the cam lobe and the adjusting screw that contacts the valve stem for excess wear. If badly worn or damaged, replace the rocker.
    4.  
    5. Inspect the fit of the rockers on the shaft. Replace rockers or the shaft as necessary.
    6.  
    7. On engines with hydraulic lash adjusters, inspect the lash adjuster face that contacts the valve stem. Replace the lash adjuster if worn or damaged.
    8.  

  2.  
  3. Lubricate the rocker arm and shafts with clean engine oil.
  4.  
  5. Observe the mating marks and reassemble the rocker arm shafts, springs, rockers and bearing caps in the reverse order of removal.
  6.  

Insert the rocker arm shaft into the front bearing cap so the notch on the end of the shaft is facing up. The No. 2, 3 and 4 bearing caps have roughly the same shape and are stamped with identification marks. When assembling the caps on the rocker shafts, make sure that they are installed in their original positions.

  1. Install the rocker arm shaft assemblies on the cylinder head and tighten the bearing cap bolts 14-15 ft. lbs. (19-21 Nm) starting from the center and working out.
  2.  
  3. Remove the special holding tools from the auto lash adjusters.
  4.  
  5. Install the rocker cover using a new gasket.
  6.  
  7. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  8.  

 
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