Tucson 2006-2008

Camshaft, Bearings & Lifters

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Bearing Replacement



Specific to:

Hyundai Tucson 2006-2008

Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover and intake manifold. For additional information, refer to Intake Manifold, removal & installation.
  4.  
  5. Disconnect the breather hose and the engine harness.
  6.  
  7. Remove the timing belt.
  8.  
  9. Remove the spark plug cables.
  10.  
  11. Loosen the cylinder head cover bolts and then remove the cylinder head cover (also called the valve cover).
  12.  
  13. Remove the camshaft sprockets.
  14.  
  15. Remove the camshaft bearing caps.
  16.  
  17. Remove the camshafts.
  18.  
  19. Rotate the crankshaft so No. 1 cylinder is at Top Dead Center (TDC) on the compression stroke).
  20.  
  21. Check the position of the rocker arm whether it is exactly installed on the lash adjuster and valve or not.
  22.  
  23. Install the camshaft dowel pin.
    WARNING
    The left and right banks of the camshafts are different. Be careful to put them in the correct position.

  24.  
  25. Look for identification markings for the left and right banks of the camshafts:
    1. Left bank Intake (IN): I. Exhaust (Ex): E.
    2.  
    3. Right bank Intake (IN): J. Exhaust (Ex): H.
    4.  

  26.  
  27. Confirm the identification mark and the number. Bearing caps for No. 3, No. 4, and No. 5 should have a front mark. Arrange the front mark upon the cylinder head while installing the bearing caps.
  28.  
  29. Use the identification mark-Intake I and Exhaust E .
  30.  
  31. Tighten each bearing cap in 2-3 steps:
    1. The 16 outer to: 14-15 ft. lbs. (19-21 Nm).
    2.  
    3. The 24 inner to: 89-106 inch lbs. (10-12 Nm).
    4.  

  32.  
  33. Install the cylinder head cover.
  34.  
  35. Install the gasket to the cylinder head cover correctly.
  36.  
  37. Clean the sealing surface on the camshaft cap.
    NOTE
    Clean the sealing surface using a scraper to prevent any oil leaks. Apply sealant to the sealing surface on the cylinder head cover and camshaft cap.


    NOTE
    Be careful of gasket escapement when installing the cylinder head cover. You must use the washer when installing the cylinder head cover bolts. Refer to Valve Covers, removal & installation.

  38.  

Inspection



Specific to:

Hyundai Tucson 2006-2008

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

    Negative battery cable
     
    Accessory drive belts
     
    Cylinder head cover
     

  4.  
  5. Inspect the camshaft lobes. Using a micrometer, measure the cam lobe height.
    1. Standard value: Intake = 1.7566 inch (44.618mm), Exhaust = 1.7527 inch (44.518mm).
    2.  
    3. Limit value: Intake = 1.7527 inch (44.518mm), Exhaust = 1.7487 inch (44.418mm).
    4.  

  6.  
  7. If the cam lobe height is less than the minimum limit value, replace the camshaft.
  8.  
  9. Inspect the camshaft journal clearance.
    1. Clean the bearing caps and camshaft journals.
    2.  
    3. Place the camshafts on the cylinder head.
    4.  
    5. Lay a strip of Plastigage®across each of the camshaft journals.
    6.  
    7. Install the bearing caps.
      NOTE
      Do not turn the camshaft.

    8.  
    9. Remove the bearing caps.
    10.  
    11. Measure the Plastigage®at its widest point. The bearing oil clearance should be within specification.

      Standard value: 0.0008-0.0024 inch (0.020-0.061mm)
       
      Limit value: 0.0039 inch (0.1mm)
       

    12.  
    13. If the oil clearance is greater than the maximum limit, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
    14.  

  10.  
  11. Completely remove the Plastigage®.
  12.  
  13. Remove the camshafts.
  14.  
  15. Inspect camshaft end play.
    1. Install the camshafts.
    2.  
    3. Using a dial indicator, measure the end play while moving the camshaft back and forth.
    4.  
    5. Camshaft end play standard value: 0.004-0.008 inch (0.1-0.2mm).
    6.  
    7. If the end play is greater than maximum limit, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
    8.  

  16.  

Removal & Installation



2.0L Engine

Specific to:

Hyundai Tucson 2006-2008

  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
     
    Cylinder head cover
     
    Timing belt
     
    Camshaft sprocket
     
    Timing chain auto tensioner
     
    Camshaft bearing caps and camshaft timing chain
     
    Intake and exhaust camshafts
     
    Mechanical lash adjusters
     



    Click image to see an enlarged view

    Fig. Removing the camshaft sprocket-2.0L engine

  4.  

To install:

  1. Install or connect the following:

    Mechanical lash adjusters in their original positions
     
    Intake and exhaust camshafts with the timing chain aligned as shown

    Click image to see an enlarged view

    Fig. Camshaft timing chain alignment marks-2.0L engine

     



    Camshaft bearing caps. Tighten to 10 ft. lbs. (14 Nm).
     
    Timing chain auto tensioner. Tighten to 72-84 inch lbs. (8-10 Nm).
     

  2.  
  3. Using Special Tool 09221-21000 seal installer, install the camshaft bearing oil seal.

    Click image to see an enlarged view

    Fig. Camshaft bearing oil seal install tool-2.0L engine

  4.  
  5. Install or connect the following:

    Camshaft sprocket and torque the bolt to 74-89 ft. lbs. (100-120 Nm)
     
    Timing belt
     
    Cylinder head cover
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Refill the cooling system to the correct level.
  8.  
  9. Refill the engine oil to the correct level.
  10.  
  11. Start the engine and check for leaks.
  12.  

2.7L Engine

Specific to:

Hyundai Tucson 2006-2008

Engine removal is not required for this procedure. Use Fender cover to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Inspect the timing belt before removing. Turn the crankshaft pulley so that the No. 1 piston is at Top Dead Center (TDC).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the side cover (A, B, C) and the engine cover (D).
  4.  
  5. Disconnect the battery terminal and the battery.

    Click image to see an enlarged view

    Fig. Remove the side cover and engine cover-2.7L engine

  6.  
  7. Remove the radiator drain plug and drain engine coolant. Remove the radiator cap to speed draining.
  8.  
  9. Remove the air cleaner assembly.
    1. Disconnect the Air Flow Sensor (AFS) connector.
    2.  
    3. Remove the breather hose from intake hose.
    4.  
    5. Remove the intake hose and air cleaner upper cover.
    6.  
    7. Remove the air cleaner lower cover.
    8.  

  10.  
  11. Remove the upper radiator hose and lower radiator hose.
  12.  
  13. Remove the heater hoses.
  14.  
  15. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold:

    Throttle position sensor (TPS) connector
     
    Idle speed actuator (ISA) connector
     
    Purge Control Solenoid Valve (PCSV) connector
     
    Knock sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Engine ground line
     
    Heated oxygen sensor (Bank 2, Sensor 1) connector
     
    Engine temperature coolant sensor connector
     
    Ignition coil connector
     
    Crankshaft Position (CKP) sensor connector
     
    Heated oxygen sensor (Bank 1, Sensor 2) connector
     
    Fuel injector connectors
     

  16.  
  17. Remove or disconnect the following:

    The fuel inlet from the delivery pipe
     
    The Purge Control Solenoid Valve (PCSV) hose
     
    The brake booster vacuum hose
     
    The accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage
     
    The auto-cruise connector and the auto-cruise cable
     
    The PCV hose
     
    The power steering pump
     
    The timing belt
     
    The cylinder head covers
     
    The camshaft sprocket
     
    The camshaft bearing caps
     
    The camshafts
     

  18.  

To install:

Thoroughly clean all parts to be assembled. Rotate the crankshaft, set the No. 1 piston at TDC.

  1. Install the camshafts.
    1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
    2.  
    3. Install the camshaft.
    4.  
    5. Install the camshaft bearing caps.
      NOTE
      Apply new engine oil to the thrust portion and journal of the camshafts. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.



      Tightening torque: M6 (38mm) bolt: 7-9 ft. lbs. (10-13 Nm)
       
      Tightening torque: M6 (50mm) bolt: 11-12 ft. lbs. (15-17 Nm)
       



      Click image to see an enlarged view

      Fig. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown-2.7L engine

    6.  

  2.  
  3. Using the SST (09214-21000), install the camshaft bearing oil seal.
  4.  
  5. Install the camshaft sprocket.
    1. Temporarily install the camshaft sprocket bolts.
    2.  
    3. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts. Tightening torque of camshaft sprocket bolt: 65-80 ft. lbs. (88-108 Nm).
    4.  

  6.  
  7. Install the semi-circular packing.
  8.  
  9. Install the cylinder head cover.
    1. Install the cylinder head cover gasket in the groove of the cylinder head cover.
      NOTE
      Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove. When installing, make sure the head cover gasket is seated securely in the corners of the recesses with no gap.

    2.  
    3. Apply liquid gasket to the head cover gasket at the corners of the recess. Use liquid gasket, Loctite® No. 5699. Check that the mating surfaces are clean and dry before applying liquid gasket. After assembly, wait at least 30 minutes before filling the engine with oil.
    4.  
    5. Install the cylinder head covers with the 16 bolts. Uniformly tighten the bolts in several passes. Tightening torque: 6-7 ft. lbs. (8-10 Nm).
    6.  

  10.  
  11. Install or connect the following:

    The timing belt
     
    The power steering pump
     
    The PCV hose
     
    The auto-cruise connector and the auto- cruise cable
     
    The accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage
     
    The brake booster vacuum hose
     
    The PCSV hose
     
    The fuel inlet from delivery pipe
     
    The fuel injector connectors
     
    Heated oxygen sensor (Bank 1, Sensor 2) connector
     
    Crankshaft position sensor connector
     
    Ignition coil connector
     
    Engine temperature coolant sensor connector
     
    Heated oxygen sensor (Bank 2, Sensor 1) connector
     
    Engine ground line
     
    Camshaft position sensor connector
     
    Knock sensor connector
     
    Injector connector
     
    The PCSV connector
     
    Idle speed actuator connector
     
    Throttle position sensor connector
     

  12.  
  13. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
  14.  
  15. Install the heater hoses.
  16.  
  17. Install the upper radiator hose and lower radiator hose.
  18.  
  19. Install the air cleaner assembly.
    1. Install the air cleaner lower cover.
    2.  
    3. Install the intake hose and air cleaner upper cover.
    4.  
    5. Install the breather hose from intake hose.
    6.  
    7. Connect the AFS connector.
    8.  

  20.  
  21. Connect the battery terminal and the battery.
  22.  
  23. Fill with engine coolant.
  24.  
  25. Install the side cover and the engine cover.
  26.  
  27. Start the engine and check for leaks.
  28.  
  29. Recheck the engine coolant level and oil level.

    Click image to see an enlarged view

    Fig. Exploded view of cylinder head and engine block-2.7L engine



    Click image to see an enlarged view

    Fig. Exploded view of cylinder head and related components-2.7L engine

  30.  

 
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