Hyundai Santa Fe (DM): CVVT & Camshaft. Repair procedures - Cylinder Head Assembly - Engine Mechanical SystemHyundai Santa Fe (DM): CVVT & Camshaft. Repair procedures

Removal

1.
Remove the cylinder head cover.
2.
Set No.1 cylinder to TDC/compression.
A.
Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.
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B.
Check that the mark(A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°)
3.
Remove the service hole bolt(A) of the timing chain cover.
4.
Release the ratchet of the timing chain tensioner by pulling the link down using a thin rod.
5.
Remove the high pressure fuel pump bracket(A).
6.
Remove the camshaft.
(1)
Remove the front camshaft bearing cap (A) with the upper bearing (B).
(2)
Remove the camshaft bearing cap (A) in the sequence shown.
(3)
Remove the camshafts (A).
7.
Disconnect the intake CVVT assembly(A) and exhaust CVVT assembly(B) from camshaft(C).

When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position D.

Inspection

CVVT Assembly
1.
Inspect CVVT assembly.
(1)
Check that the CVVT assembly will not turn.
(2)
Apply vinyl tape to the retard hole like the one indicated by the arrow in the illustration.
Verify that the tape holds and put air through the port of the camshaft.
[Intake]

[Exhaust]
(3)
Wind tape around the tip of the air gun and apply air of approx. 150 kPa(1.5 kgf/cm², 21 psi) to the port of the camshaft.
(Perform this in order to release the lock pin.)
When the oil splashes, wipe it off with a shop rag and the likes.
(4)
With air applied, as in step(3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
(5)
Turn the CVVT assembly back and forth and check the movable range and that there is no disturbance.
Standard:
Should move smoothly in a range from about
22.5° (Intake) / 20.0° (Exhaust)
(6)
Turn the intake CVVT assembly with your hand and lock it at the maximum retard angle position (counter clockwise).
(7)
Turn the exhaust CVVT assembly with your hand and lock it at the maximum advance angle position (clockwise).
Camshaft
1.
Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.10 ~ 44.30 mm (1.7362 ~ 1.7440 in.)
Exhaust : 44.90 ~ 45.10 mm (1.7677 ~ 1.7756 in.)

If the cam lobe height is less than standard, replace the camshaft.
2.
Inspect the camshaft journal clearance.
(1)
Clean the bearing caps and camshaft journals.
(2)
Place the camshafts on the cylinder head.
(3)
Lay a strip of plastigage across each of the camshaft journal.
(4)
Install the bearing caps.
Do not turn the camshaft.
(5)
Remove the bearing caps.
(6)
Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake :
No.1 : 0.022 ~ 0.057 mm (0.00087 ~ 0.00224 in.)
No.2, 3, 4, 5 : 0.045 ~ 0.082 mm (0.00177 ~ 0.00323 in.)
Exhaust:
No.1 : 0 ~ 0.032 mm (0 ~ 0.00126 in.)
No.2, 3, 4, 5 : 0.045 ~ 0.082 mm (0.00177 ~ 0.00323 in.)
[Limit]
Intake:
No.1 : 0.090 mm (0.00354 in.)
No.2, 3, 4, 5 : 0.120 mm (0.00472 in.)
Exhaust :
No.1 : 0.090 mm (0.00354 in.)
No.2, 3, 4, 5 : 0.120 mm (0.00472 in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7)
Completely remove the plastigage.
(8)
Remove the camshafts.
3.
Inspect the camshaft end play.
(1)
Install the camshafts.
(2)
Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.04 ~ 0.16 mm (0.0016 ~ 0.0063 in.)
[Limit] : 0.20 mm (0.0078 in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3)
Remove the camshafts.
Exhaust Camshaft Bearing
1.
Check the cylinder head bore mark.
Cylinder Head Bore Identification Mark

Cylinder Head Specifications
Class
 Mark
 Exhaust No.1 Inside Diameter Of Cylinder Head Bore
a
 A
 40.000 ~ 40.008 mm
(1.57480 ~ 1.5751in.)
b
 B
 40.008 ~ 40.016 mm
(1.57511 ~ 1.57543 in.)
c
 C
 40.016 ~ 40.021 mm
(1.57543 ~ 1.57563 in.)

2.
Select class of camshaft bearing same as class of cylinder head as shown on the table below.
Exhaust Camshaft Bearing Identification Mark

Exhaust Camshaft Bearing Specifications
Cylinder
Head Bore
Class
 Bearing Class For Installing (Color)
 Thickness Of Bearing
a (A)
 C (Green)
 1.996~2.000 mm
(0.07858~0.07874 in.)
b (B)
 B (None color)
 2.000~2.004 mm
(0.07874~0.07890 in.)
c (C)
 A (Black)
 2.004~2.008 mm
(0.07890~0.07905 in.)

Oil clearance : 0 ~ 0.032 mm (0 ~ 0.00126 in.)

Installation

1.
Install the intakeCVVT assembly(A), exhaust CVVT assembly(B) and camshaft(C).
Tightening torque :
53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)

When installing the CVVT assembly bolt, fix the camshaft by wrench at position D.
2.
Install the camshafts.
Apply a light coat of engine oil on camshaft journals.
(1)
Install the exhaust camshaft lower bearing (A).
(2)
Install the camshafts (A).
(3)
Install the timing chain
Check that the mark(A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration.
(4)
Install the exhaust camshaft upper bearing (A) to the front bearing cap.
3.
Install camshaft bearing caps (A) in their proper locations.
Tightening order
Group A → Group B → Group C.
Tightening torque :
Step 1
M6 : 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
M8 : 14.7 N.m (1.5 kgf.m, 10.8 lb-ft)
Step 2
M6 : 10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)
M8 : 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)

4.
Install the high pressure fuel pump(A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

5.
Install the ratchet of the timing chain tensioner by pushing the link up using a thin rod.
6.
Install the service hole bolt of the timing chain cover.
Tightening torque :
11.7 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.6 ~ 10.8 lb-ft)

The bolt must not be reused once it has been assembled.
7.
Install the cylinder head cover.

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