1. |
Remove the engine cover and intake
manifold.

|
2. |
Disconnect the breather hose and the engine
harness. |
3. |
Remove the power steering pulley, air
conditioner pulley, crankshaft pulley, idler pulley and tensioner
pulley. |
4. |
Remove the timing belt
cover. |
5. |
Loosen the auto
tensioner. |
6. |
Remove the timing belt from the camshaft
sprocket. |
7. |
Remove the spark plug
cables. |
8. |
Loosen the cylinder head cover bolts and then
remove it.

|
9. |
Remove the camshaft
sprockets. |
10. |
Remove the camshaft bearing caps.

|
11. |
Remove the camshafts.

|
1. |
Check the camshaft journals for wear. If the
journals are badly worn out, replace the
camshaft. |
2. |
Check the cam lobes for damage. If the lobe is
damaged or excessively worn out, replace the camshaft.
Cam
height
[Standard]
Intake : 43.95 ~ 44.15mm (1.7303 ~
1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~
1.7382in.)
[Limit]
Intake/Exhaust : 43.45mm (1.7106
in.)
|

|
3. |
Check the cam surface for abnormal wear or
damage, and replace if necessary. |
4. |
Check each bearing for damage. If the bearing
surface is excessively damaged, replace the cylinder head assembly
or camshaft bearing cap, as necessary.
Camshaft end play : 0.1 ~ 0.15mm (0.0039
~ 0.0059in.)
| |
Oil Seal (Camshaft front)
1. |
Check the lips for wear. If lip threads are
worn out, replace the oil seal with new
one. |
2. |
Check a contact surface of oil seal lip on
camshaft. If there stratified wear, replace the
camshaft. |
HLA (Hydraulic Lash Adjuster)
With the HLA filled with
engine oil, hold A and press B by hand. If B moves, replace the
HLA.

Problem
|
Possible cause
|
Action
|
1. Temporary
noise when starting a cold engine
|
Normal
|
This noise
will disappear after the oil in the engine reaches the normal
pressure.
|
2. Continuous
noise when the engine is started after parking more than 48
hours.
|
Oil leakage of
the high pressure chamber on the HLA,allowing air to get
in.
|
Noise
will disappear within 15 minutes when engine runs at 2000-3000
rpm. If it doesn't disappear, refer to
step 7 below.
|
3. Continuous
noise when the engine is first started after rebuilding cylinder
head.
|
Insufficient
oil in cylinder head oil gallery.
|
4. Continuous
noise when the engine is started after excessivly craking the engine
by the starter motor or band.
|
Oil
leakage of the high-pressure chamber in the HLA, allowing air to get
in. Insufficient oil in the
HLA.
|
5. Continuous
noise when the engine is running after changing the
HLA.
|
Do not run engine at a speed higher than
3000 rpm, as this may damage the
HLA. | |
6.Continuous noise during idle after high engine
speed.
|
Engine oil
level too high or too low.
|
Check oil
level. Drain or add oil as
necessary.
|
Excessive
amount of air in the oil at high engine speed.
|
Check oil
supply system.
|
Deteriorated
oil.
|
Check oil
quality. If deteriorated, replace with
specitied type.
|
7.
Noise cotinues for more than 15 minutes.
|
Low oil
pressure.
|
Check oil
pressure and oil supply syste, of each part of
engine.
|
Faulty
HLA.
|
Remove the
cylinder head cover and press HLA down by hand. If it moves, replace the
HLA.
|
Timing chain
Check the bushing and
plate of timing chain for wear. Replace if there is severe
wear.

2. |
Align the camshaft timing chain with the
intake timing chain sprocket and exhaust timing chain sprocket as
shown in the illustration.

|
3. |
Install the camshafts after lubricating the
journals of the camshaft with engine oil.
To check the press fit, the camshaft
(IN) and timing chain sprocket should be separable by a force
greater than 1000kg (MIN.)at room temperature.

| |
4. |
Install the bearing caps. Check the markings
on the caps for intake/exhaust identification symbol.
I : Intake camshaft
E : Exhaust camshaft

|
5. |
Tighten the bearing caps to the specified
torque in two or three increments as shown.
Tightening
torque
Bearing cap bolt
M6 (50mm) : 14 ~ 16Nm (140 ~ 160kg.cm,
10 ~ 12lb.ft)
M6 (38mm) : 10 ~ 12Nm (100 ~ 120kg.cm, 7
~ 9lb.ft)
|

|
6. |
Using the special tool, the camshaft oil seal
installer (09221-21000), install the camshaft oil seal. Be sure to
apply engine oil to the externalsurface of the oil
seal.
Insert the oil seal along the camshaft front
end and install it with a hammer until it is seated.

|
7. |
Install the camshaft sprocket to the specified
torque.
Tightening
torque
Camshaft sprocket bolt :
90 ~ 110Nm (900 ~ 1100kg.cm, 65 ~
80lb.ft)
| |
8. |
Install the cylinder head cover.
Tightening
torque
Cylinder head cover bolts :
8 ~ 10Nm (80 ~ 100kg.cm, 5.8 ~
7.2lb.ft)
|
(1) |
Tighten all bolts temporarily to half of
the specified torque in the sequence
1.2.3.4.5.6.7.8. |
(2) |
Retighten all bolts to the specified
torque.

| |
9. |
Install the spark plug cables and, center
cover. |
10. |
Install the timing belt and then tighten the
auto tensioner pulley. |
11. |
Install the timing belt
cover. |
12. |
Install the power steering pulley, air
conditioner pulley, crankshaft pulley and tensioner
pulley.

|
13. |
Connect the breather hose and engine
harness. |
14. |
Install the intake manifold and engine
cover.

|