Hyundai Elantra HD: Repair procedures - Cylinder Head Assembly - Engine Mechanical System - Hyundai Elantra HD 2006–2010 Service ManualHyundai Elantra HD: Repair procedures

Removal

•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
•
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
•
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 the cylinder head.
•
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1.
Disconnect the negative terminal (A) from the battery and remove the battery (B).
2.
Remove the engine cover (A).
3.
Drain the engine coolant.
Remove the radiator cap to speed draining.
4.
Remove the intake air hose and air cleaner assembly.
(1)
Disconnect the PCM connectors (A).
(2)
Disconnect the MAF connector (B).
(3)
Disconnect the breather hose (C) from air cleaner hose (D).
(4)
Remove the intake air hose and air cleaner assembly (E).

5.
Remove the upper radiator hose(A) and lower radiator hose(B).
6.
Remove the heater hoses (A).
7.
Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
(1)
OCV(Oil control Valve) connector (A).
(2)
Oil temperature sensor (OTS) connector (B).
(3)
Engine coolant temperature (ECT) sensor connector (C).
(4)
Ignition coil connector (D).
(5)
TPS(Throttle Position Sensor) connector (A).
(6)
ISA(Idle Speed Actuator) connector (B).
(7)
CMP(Camshaft Position Sensor) connector (C).
(8)
Four fuel injector connectors.
(9)
Knock sensor connector (D).
(10)
PCSV(Purge Control Solenoid Valve) connector (E).
(11)
Front heated oxygen sensor connector.
8.
Remove the fuel inlet hose (A) from delivery pipe.
9.
Remove the PCSV hose.
10.
Remove the brake booster vacuum hose.
11.
Remove the accelerator cable and the auto-cruise cable by loosening the locknut, then slip the cable end out of the throttle linkage.
12.
Remove the spark plug cable.
13.
Remove the PCV hose.
14.
Remove the cylinder head cover.
15.
Remove the timing belt.
16.
Remove the exhaust manifold.
17.
Remove the intake manifold.
18.
Remove the camshaft sprocket.
19.
Remove the timing chain auto tensioner (A).
20.
Remove the camshaft bearing caps (A) and camshafts (B).
21.
Remove the OCV(oil control valve) (A).
22.
Remove the OCV(oil control valve) filter (A).
23.
Remove the cylinder head bolts, then remove the cylinder head.
(1)
Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.

Head warpage or cracking could result from removing bolts in an incorrect order.
(2)
Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Replacement

Valve Guide
1.
Using the SST(09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.
2.
Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3.
Using the SST(09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in length.
Over size mm(in.)
 Size mark
 Oversize valve guide hole size mm(in.)
0.05 (0.002)
 5
 11.05 ~ 11.068
(0.4350 ~ 0.4357)
0.25 (0.010)
 25
 11.25 ~ 11.268
(0.4429 ~ 0.4436)
0.50 (0.020)
 50
 11.50 ~ 11.518
(0.4528 ~ 0.4535)

Valve guide length
Intake : 46mm (1.8in.)
Exhaust : 54.5mm (2.15in.)

Before the valve guide is press-fitted using the SST (09221-3F100A/B), remove the valve spring seat to install the valve guide correctly.
4.
After the valve guide is press-fitted, insert a new valve and check for proper stem -to-guide clearance.
5.
After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary.

Disassembly

Identify MLA(Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.
1.
Remove MLAs (A).
2.
Remove valves.
(1)
Using SST(09222-28000, 09222-28100), compress the valve spring and remove retainer lock.
(2)
Remove the spring retainer.
(3)
Remove the valve spring.
(4)
Remove the valve.
(5)
Remove the using needle-nose pliers, remove the oil seal.
(6)
Using a magnetic finger, remove the spring seat.

Inspection

Cylinder Head
1.
Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.03mm(0.0012 in)
Limit : 0.06 mm ( 0.0024 in)

2.
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Valve And Valve Spring
1.
Inspect valve stems and valve guides.
(1)
Using a caliper gauge, measure the inside diameter or the valve guide.
Valve guide inside.
(2)
Using a micrometer, measure the diameter of the valve stem.
(3)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~ 0.0020in)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in)
[Limit]
Intake : 0.1mm (0.0040in)
Exhaust : 0.13mm (0.0051in)
If the clearance is greater than maximum, replace the valve and valve guide.
2.
Inspect valves.
(1)
Check the valve is ground to the correct valve face angle.
(2)
Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3)
Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.6 mm(0.0630 in)
Exhaust : 1.8 mm(0.0709 in)
[Limit]
Intake : 1.45 mm(0.0571 in)
Exhaust : 1.65 mm(0.0650 in)

(4)
Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3.
Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4.
Inspect valve springs.
(1)
Using a steel square, measure the out-of-square of the valve spring.
(2)
Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 48.86mm (1.9236 in)
Load :
18.8±0.9kg/39.0mm (41.4±2.0lb/1.5354in)
41.0±1.5kg/30.5mm (90.4±3.3lb/1.2008in)
Out-of-square : 1.5°
[Limit]
Out-of-square : 3°

If the free length is not as specified, replace the valve spring.
Camshaft
1.
Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.518~44.718mm (1.7527~1.7605in)
Exhaust : 44.418~44.618mm (1.7487~1.7566in)

If the cam lobe height is less than minimum, replace the camshaft.
2.
Inspect 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] : 0.02 ~ 0.061mm(0.0008 ~ 0.0024in)
[Limit] : 0.1mm(0.0039in)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(7)
Completely remove the plastigage.
(8)
Remove the camshafts.
3.
Inspect 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] : 0.1 ~ 0.15mm(0.0039 ~ 0.0059in)

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3)
Remove the camshafts.
CVVT Assembly
1.
Inspect CVVT assembly.
(1)
Check that the CVVT assembly will not turn.
(2)
Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.
(3)
Wind tape around the tip of the air gun and apply air of approx. 100kpa(1kgf/cm², 14psi) to the port of the camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)
When the oil splashes, wipe it off with a shop rag and the likes.
(4)
Under the condition of (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)
Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no disturbance.
Standard : Movable smoothly in the range about 20°
(6)
Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

Reassembly

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1.
Install valves.
(1)
Install the spring seats.
(2)
Using SST(09222-22001), push in a new oil seal.
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(3)
Install the valve, valve spring and spring retainer.
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.
(4)
Using the SST(09222-28000,09222-28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(5)
Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
2.
Install MLAs.
Check that the MLA rotates smoothly by hand.

Installation

•
Thoroughly clean all parts to be assembled.
•
Always use a new head and manifold gasket.
•
The cylinder head gasket is a metal gasket. Take care not to bend it.
•
Rotate the crankshaft, set the No. 1 piston at TDC.
1.
Install the cylinder head gasket (A) on the cylinder block.

Be careful of the installation direction.
2.
Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3.
Install cylinder head bolts.
(1)
Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2)
Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Components and Components Location
Components 1. Cylinder block 2. Cylinder head gasket 3. Cylinder head 4. Cylinder head bolt 5. Gasket 6. Cylinder head cover 1 ...