Hyundai Santa Fe (TM): Cylinder Head Assembly - Engine Mechanical SystemHyundai Santa Fe (TM): Cylinder Head Assembly

Components and components location

Components

1. Camshaft front bearing cap
2. Camshaft bearing cap
3. OCV & Center bolt
4. Exhaust CVVT assembly
5. Exhaust camshaft
6. Intake camshaft
7. Intake CVVT assembly
8. Cam carrier
9. Cylinder head
10. Swing arm
11. Hydraulic lash adjuster (HLA)
12. Cylinder head gasket
13. Retainer lock
14. Retainer
15. Valve spring
16. Valve stem seal
17. Valve

Cylinder Head Cover. Components and components location

Components

1. Cylinder head cover
2. Cylinder head cover gasket
3. Cylinder head cover center bolt gasket

Cylinder Head Cover. Repair procedures

Removal
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
  
Remove the engine cover on room temperature.
Do not disengage both front and rear mounting point at the same time.
3.
Disconnect the wiring connectors and harness clamps and remove the connector brackets around the cylinder head cover.
4.
Remove the ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
5.
Disconnect the breather hose (A).

6.
Remove the cylinder head cover (A).

Installation
1.
Install cylinder head cover.
(1)
The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2)
After applying sealant, it should be assembled within 5 minutes.
Bead width : Ø 4.0 - 5.0 mm (0.16 - 0.20 in.)

(3)
Install the cylinder head cover (A) by tightening the bolts as following method.
Tightening torque
1st step : 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
2nd step : 7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)

  
Do not reuse cylinder head cover gasket.
The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
2.
Connect the breather hose (A).

3.
Install the ignition coils.
(Refer to Engine Electrical System - "Ignition Coil")
4.
Connect the wiring connectors and harness clamps and remove the connector brackets around the cylinder head cover.
Tightening torque
6.9 - 9.8 N.m (0.7 - 1.0 kgf.m, 5.1 - 7.2 lb-ft)
5.
Installation is in the reverse order of removal.

CVVT & Camshaft. Description and operation

Description
Continuous Variable Valve Timing (CVVT) system advances or retards the valve timing of the intake and exhaust valve in accordance with the ECM control signal which is calculated by the engine speed and load.
By controlling CVVT, the valve over-lap or under-lap occurs, which makes better fuel economy and reduces exhaust gases (NOx, HC) and improves engine performance through reduction of pumping loss, internal EGR effect, improvement of combustion stability, improvement of volumetric efficiency, and increase of expansion work.
This system consist of
the CVVT Oil Control Valve (OCV) which supplies the engine oil to the cam phaser or runs out the engine oil from the cam phaser in accordance with the ECM PWM (Pulse With Modulation) control signal,
and the Cam Phaser which varies the cam phase by using the hydraulic force of the engine oil.
The engine oil getting out of the CVVT oil control valve varies the cam phase in the direction (Intake Advance/Exhaust Retard) or opposite direction (Intake Retard/Exhaust Advance) of the engine rotation by rotating the rotor connected with the camshaft inside the cam phaser.

Operation Principle
The CVVT has the mechanism rotating the rotor vane with hydraulic force generated by the engine oil supplied to the advance or retard chamber in accordance with the CVVT oil control valve control.
  
The variable force solenoid (VFS) changes its force depending on the PWM duty to control the stroke of the OCV.
It also controls the lock, unlock, advanced, retarded, and holding functions.

[CVVT System Mode]

(1) Low Speed / Low Load
(2) Part Load


(3) Low Speed / High Load
(4) High Speed / High Load



Driving
Condition
Exhaust Valve
Intake Valve
Valve
Timing
Effect
Valve
Timing
Effect
(1) Low Speed
/Low Load
Completely
Advance
* Valve Under-lap
* Improvement of combustion stability
Completely
Retard
* Valve Under-lap
* Improvement of combustion stability
(2) Part Load
Retard
* Increase of expansion work
* Reduction of pumping loss
* Reduction of HC
Retard
* Reduction of pumping loss
(3) Low Speed
/High Load
Retard
* Increase of expansion work
Advance
* Prevention of intake back flow (Improvement of volumetric efficiency)
(4) High Speed
/High Load
Advance
* Reduction of pumping loss
Retard
* Improvement of volumetric efficiency

CVVT & Camshaft. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
CVVT & Cam Shaft
1.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2.
Remove the oil control valve (OCV) and center bolt (A).
[Intake oil control valve (OCV) and Center Bolt]

[Exhaust oil control valve (OCV) and Center Bolt]

  
To prevent impurities from entering exhaust oil control valve (OCV) & center bolt, wear rubber gloves.
When removing the exhaust oil control valve (OCV) and center bolt, hold the hexagonal portion (A) on the camshaft with a wrench to prevent the camshaft from rotating.
[Intake CVVT]

[Exhaust CVVT]

3.
Remove the intake CVVT (A).

4.
Remove the exhaust CVVT (A).

5.
Remove the camshaft front bearing cap (A) and camshaft bearing caps (B).

6.
Remove the camshaft (A).
[Intake Camshaft]

[Exhaust Camshaft]

CVVT & Cam Shaft Assembly
1.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
2.
Remove the camshaft front bearing cap (A) and camshaft bearing caps (B).

3.
Remove the intake camshaft & CVVT assembly (A).

4.
Remove the exhaust camshaft & CVVT assembly (A).

Inspection
Camshaft
1.
Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 39.7 - 39.9 mm (1.5630 - 1.5709 in.)
Exhaust : 37.9 - 38.1 mm(1.4921 - 1.5000 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
Intake :
NO.1 : 0.037 - 0.065mm (0.00146 - 0.00256 in)
NO.2,3,4,5 : 0.037 - 0.067mm (0.00146 - 0.00264 in)
Exhaust:
NO.1: 0.037 - 0.065mm (0.00146 - 0.00256 in)
NO.2,3,4,5 : 0.037 - 0.067mm (0.00146 - 0.00264 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
0.09 - 0.23 mm (0.00354 - 0.00091 in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3)
Remove the camshafts.
Installation
CVVT & Cam Shaft
1.
Install the camshaft (A).
[Intake Camshaft]

[Exhaust Camshaft]

2.
Install the camshaft front bearing cap (A) and camshaft bearing caps (B).

  
When installing the camshaft front bearing cap and camshaft bearing caps, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Tightening torque :
Step 1
M8 Bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
M6 Bolts : 4.9 - 7.8 N.m (0.5 - 0.8 kgf.m, 3.6 - 5.8 Ib-ft)
Step 2
M8 Bolts : 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
M6 Bolts : 11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)

3.
Install the exhaust CVVT (A).

4.
Install the intake CVVT (A).

5.
Install the oil control valve (OCV) and center bolt (A).
Tightening torque :
27.4 - 31.3 N.m (2.8 - 3.2 kgf.m, 20.2 - 23.1 IB-ft) + 30°
[Intake oil control valve (OCV) and Center Bolt]

[Exhaust oil control valve (OCV) and Center Bolt]

  
To prevent impurities from entering exhaust oil control valve (OCV) & center bolt, wear rubber gloves.
When installing the exhaust oil control valve (OCV) and center bolt, hold the hexagonal portion (A) on the camshaft with a wrench to prevent the camshaft from rotating.
[Intake CVVT]

[Exhaust CVVT]

6.
Install the timing chain.
(Refer to Timing System - "Timing Chain")
CVVT & Cam Shaft Assembly
1.
Install the exhaust camshaft & CVVT assembly (A).

2.
Install the intake camshaft & CVVT assembly (A).

3.
Install the camshaft front bearing cap (A) and camshaft bearing caps (B).

  
When installing the camshaft front bearing cap and camshaft bearing caps, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Tightening torque :
Step 1
M8 Bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
M6 Bolts : 4.9 - 7.8 N.m (0.5 - 0.8 kgf.m, 3.6 - 5.8 Ib-ft)
Step 2
M8 Bolts : 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
M6 Bolts : 11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)

4.
Install the timing chain.
(Refer to Timing System - "Timing Chain")

Cylinder Head. Repair procedures

Removal
  
Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
  
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.
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
3.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
4.
Drain the coolant.
(Refer to Cooling System - "Coolant")
5.
Drain the engine oil.
(Refer to Lubrication System - "Engine Oil")
6.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
7.
Remove the battery tray.
(Refer to Engine Electrical System - "Battery")
8.
Disconnect the radiator upper hose (A).

9.
Disconnect the brake vacuum hose (A).

10.
Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).

11.
Remove the delivery pipe.
(Refer to Engine Control / Fuel System - "Delivery Pipe")
12.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
13.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
14.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
15.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
16.
Remove the camshaft front bearing cap (A) and camshaft bearing caps (B).

17.
Remove the intake camshaft & CVVT assembly (A).

18.
Remove the exhaust camshaft & CVVT assembly (A).

19.
Remove the cam carrier (A).

20.
Remove the hydraulic lash adjuster (HLA) (A) and swing arm (B).

21.
Remove the spark plug.
(Refer to Engine Electrical System - "Spark Plug")
22.
Remove the cylinder head.
(1)
Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

  
Head warpage or cracking could result from removing bolts in an incorrect order.
(2)
Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

  
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(3)
Remove the cylinder head gasket (A).

  
Do not reuse the cylinder head gasket.
Disassembly
1.
Remove the valves.
(1)
Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

(2)
Remove the spring retainer.
(3)
Remove the valve spring.
(4)
Remove the valve.
(5)
Using needle-nose pliers, remove the valve stem seal.
  
Do not reuse old valve stem seals.
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 0.05 mm (0.0019 in.) for total area
Less than 0.02 mm (0.0007 in.) for a section of 100 mm (3.9370 in.) X 100 mm (3.9370 in.)
Flatness of manifold mounting surface (Intake/Exhaust)
Standard : Less than 0.10 mm (0.0039 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 of the valve guide.
Valve guide inner diameter
Intake / Exhaust :
5.500 - 5.512 mm (0.21654 - 0.21701 in.)

(2)
Using a micrometer, measure the diameter of the valve stem.
Valve stem outer diameter
Intake : 5.460 - 5.475 mm (0.2150 - 0.2156 in.)
Exhaust : 5.453 - 5.465 mm (0.2147 - 0.2152 in.)

(3)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 - 0.047 mm (0.00078 - 0.00185 in.)
Exhaust : 0.030 - 0.054 mm (0.00118 - 0.00212 in.)
[Limit]
Intake : 0.070 mm (0.00275 in.)
Exhaust : 0.090 mm (0.00354 in.)
If the clearance is greater than maximum, replace the valve or cylinder head.
2.
Inspect the 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.
Valve head thickness (Margin)
[Standard]
Intake : 0.8 mm (0.03150 in.)
Exhaust : 0.8 mm (0.03150 in.)

If the margin thickness is less than minimum, replace the valve.
(4)
Check the valve length.
Valve length
[Standard]
Intake : 108.378 mm (4.2669 in.)
Exhaust :119.878 mm (4.7196 in.)
[Limit]
Intake : 108.228 mm (4.2609 in.)
Exhaust : 119.728 mm (4.7137 in.)
(5)
Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3.
Inspect the valve seats
(1)
Check the valve seat for evidence of overheating and improper contact with the valve face. Replace the cylinder head if necessary.
(2)
Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
4.
Inspect the 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 : 52.51 mm (2.0673 in.)
Out-of-square : Less than 1.5°

If the free length is not as specified, replace the valve spring.
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)
After applying engine oil to the valve stem seal, install a new valve stem seal using the special tool (09222-2B100).

  
Always use new valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.
(2)
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.
(3)
Using the SST (09222-3K000, 09222-3K100), 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.

(4)
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 the MLAs after appling engine oil.
Installation
  
Thoroughly clean all parts to be assembled.
Always use a new cylinder head gasket and manifold gasket.
Always use a new cylinder head bolt and cylinder head bolt washer.
The cylinder head and exhaust manifold is a metal gasket. Take care not to bend it.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1.
Install the cylinder head.
(1)
Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the cylinder block and the cylinder head.
(2)
Apply liquid sealant on the upper surface of the cylinder block.
Width : 2.0 - 3.0 mm (0.0787 - 0.1181 in.)
Specification : MS721-40 TYPE "AA" or "AAO"

(3)
Install the cylinder head gasket (A) to the cylinder block.

  
Be careful of the installation direction.
(4)
Apply liquid sealant on the upper surface of the cylinder head gasket.
Width : 2.0 - 3.0 mm (0.0787 - 0.1181 in.)
Specification : MS721-40 TYPE "AA" or "AAO"

2.
Install the cylinder head assembly.
(1)
Place the cylinder head assembly (A) quietly in order not to damage the gasket with the bottom part of the end.

(2)
Using SST (09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4 - 36.3 N.m (3.3 - 3.7 kgf.m, 23.9 - 26.8 lb-ft) + [90° - 94°] + [110° - 114°]

  
Do not reuse the cylinder head bolts.
Do not apply engine oil on the bolt threads to achieve correct torque.
Remove the extruded sealant within 5 minutes after installing cylinder head bolts.
The engine running or pressure test should not be performed within 30minutes after installing cylinder head bolts.
Be careful not to change the installing position of the preassembled washer bolts and non-preassembled washer bolts.
3.
Install the spark plugs.
(Refer to Engine Electrical System - "Spark Plug")
4.
Install the hydraulic lash adjuster (HLA) (A) and the swing arm (B).

5.
Install the cam carrier to the cylinder head.
(1)
Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the bottom surface of the cam carrier and top surface of the cylinder head.
(2)
After applying liquid sealant on the bottom surface of the cam carrier, Continuous bead of sealant should be applied to prevent any path from oil leakage.
Width : 2.0 - 3.0 mm (0.0787 - 0.1181 in.)
Specification : MS721-40 TYPE "AA" or "AAO"

  
When installing the cam carrier to the cylinder head, make sure to prevent the sealant from entering the hole (A) and the positive crankcase ventilation (PCV).

6.
Install the cam carrier (A).
Tightening torque :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

  
Assemble the cam carrier within 5 minutes after applying sealant.
Assemble the camshaft bearing cap within 5 minutes after assembling the cam carrier.
The engine running or pressure test should not be performed within 30 minutes after assembling the cam carrier.
After installing the cam carrier to the cylinder head, check whether there are sealants in the hole of the oil level gauge and the positive crankcase ventilation (PCV).
7.
Install the intake CVVT & camshaft assembly (A).

8.
Install the exhaust CVVT & camshaft assembly (A).

9.
Install the camshaft front bearing cap (A) and camshaft bearing caps (B).

  
When installing the camshaft front bearing cap and camshaft bearing caps, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Tightening torque :
Step 1
M8 Bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
M6 Bolts : 4.9 - 7.8 N.m (0.5 - 0.8 kgf.m, 3.6 - 5.8 Ib-ft)
Step 2
M8 Bolts : 18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
M6 Bolts : 11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)

10.
Install the other parts in the reverse order of removal.
11.
Fill with engine coolant.
(Refer to Cooling System - "Coolant")
12.
Refill engine with engine oil.
(Refer to Lubrication System - "Engine Oil")
Timing System
Components and components location Components 1. Front oil seal 2. Timing chain cover 3. Timing chain 4. Cam to cam bracket 5. Timing chain guide 6. Timing chain tensioner arm 7. Timing chain tensioner ...

Cylinder Block
Drive Plate. Repair procedures Removal and Installation    • Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising ...

See also:

Driver assistance system
Due to the infotainment software update, the description of each function of the driver assistance system may differ from the owner's manual. In this case, for detailed information on updates, refer to ...

Front Door Inside Handle. Repair procedures
Replacement 1. Remove the front door trim. 2. After loosening the mounting screws, then remove the front door inside handle (A). 3. Install in the reverse order of removal. • Make sure the door locks/unlocks ...

General Information. Troubleshooting
Troubleshooting Symption Suspect area Remedy Engine misfire with abnormal internal lower engine noises. Worn crankshaft bearings Loose or out of specification engine flywheel Replace the crankshaft and ...