Disassembly
1. Using special tool 09221–32001, 09221–11000 in the sequence shown in the figure, in 2–3 passes, unscrew the cylinder head mounting bolts.
2. Using special tool 09222–28000, 09222–28100, compress the valve spring and remove the crackers from the valve stem. Slowly release the spring compressor and remove the valve spring, spring retainer and valve from the cylinder head.
Note: Prepare numbered plastic bags or containers for storing valves.
3. Using pliers 09222–29000, remove the oil deflector cap.
Caution: Do not reuse the valve stem seal.
Examination
Cylinder head
1. Inspect the cylinder head for damage, cracks, oil and coolant leaks. Replace the cylinder head if necessary.
2. Remove scale, sealant and carbon deposits. Blow out the lubrication channels with compressed air.
3. Using a metal ruler and feeler gauge in six directions A, B... check the flatness of the cylinder head. If necessary, regrind the cylinder head.
- Standard deviation from flatness: less than 0.03 mm.
- Maximum permissible deviation from flatness: 0.05 mm.
Valves
1. Clean the valve with a wire brush.
2. Inspect each valve for wear, damage and deformation in areas A and B and repair or replace if necessary. If the end of the rod is pitted or worn, re-chamfer as necessary. This restoration should be limited to minimal metal removal.
Also check the thickness of the working edges.
Valve working edge thickness:
- Inlet valves: 1.15 mm:
- 1.8 and 2.0 l engines: 1.15 mm;
- 1.6L engines: 1.1 mm.
- Exhaust valves:
- 1.8 and 2.0 l engines: 1.35 mm;
- 1.6L engines: 1.3mm.
Maximum permissible thickness of the valve working edge:
- Inlet valves: 0.8 mm;
- Exhaust valves: 1.0 mm.
Valve spring
1. Inspect each valve spring for cracks or damage. Measure the length of the spring in its free state.
2. Place the spring on a flat horizontal surface and measure the deviation of the top of the spring from the vertical plane.
Engines 1.8 and 2.0 l
- Spring length without load: 48.86 mm
- Spring length under 18.3 kg load: 39 mm
- Spring length under 40.0 kg load: 30.5 mm
- Permissible deviation of the spring from the vertical plane: no more than 1.5°
- Maximum permissible deviation of the spring from the vertical plane: no more than 3°
1.6L engines
- Spring length without load: 44 mm
- Spring length under 21.6 kg load: 35 mm
- Spring length under 45.1 kg load: 27.2 mm
- Permissible deviation of the spring from the vertical plane: no more than 1.5°
- Maximum permissible deviation of the spring from the vertical plane: no more than 4°
Valve guide bushings
Check the clearance between the valve stem and the valve guide. If the clearance exceeds the maximum permissible value, replace the valve guide bushing with a bushing of an increased repair size.
Engines 1.8 and 2.0 l
Clearance between valve stem and valve guide:
- Inlet valves: 0.02–0.05 mm
- Exhaust valves: 0.035–0.065 mm
Maximum permissible clearance between the valve stem and the valve guide bushing:
- Inlet valves: 0.1 mm
- Exhaust valves: 0.13 mm
1.6L engines
Clearance between valve stem and valve guide:
- Intake valves: 0.03–0.06 mm
- Exhaust valves: 0.05–0.08 mm
Maximum permissible clearance between the valve stem and the valve guide bushing:
- Inlet valves: 0.1 mm
- Exhaust valves: 0.15 mm
Valve seat insert
Check the valve seat for overheating and damage to the working surface in contact with the valve disc. Repair or replace the valve seat if necessary.
Before replacing or repairing the valve seat, check the valve guide for wear. If the valve guide is worn, replace it.
Replacing the valve seat
Any valve seat insert that has worn to the limit must be replaced at room temperature by cutting off the wall as shown in the figure.
2. After removing the old valve seat, it is necessary to bore the seat to fit the increased valve seat size. Dimensions for processing are given in the table.
Increased dimensions of the valve seat insert for 1.8 and 2.0 L engines
Description | Size mark | Saddle height, mm | Cylinder head socket diameter, mm |
| Inlet valve seat increased by 0.3 mm | 30 | 7,5–7,7 | 33,300–33,325 |
| Intake valve seat increased by 0.6 mm | 60 | 7,8–8,0 | 33,600–33,625 |
| Exhaust valve seat increased by 0.3 mm | 30 | 7,9–8,1 | 28,800–28,821 |
| Exhaust valve seat increased by 0.6 mm | 60 | 8,2–8,4 | 29,100–29,121 |
Increased dimensions of the valve seat insert for 1.6L engines
Description | Size mark | Saddle height, mm | Cylinder head socket diameter, mm |
| Inlet valve seat increased by 0.3 mm | 30 | 5,1–5,3 | 30,700–30,721 |
| Intake valve seat increased by 0.6 mm | 60 | 5,4–5,6 | 31,000–31,021 |
| Exhaust valve seat increased by 0.3 mm | 30 | 6,2–6,4 | 27,300–27,3211 |
| Exhaust valve seat increased by 0.6 mm | 60 | 6,5–6,7 | 27,600–27,621 |
3. Heat the cylinder head to 250°C and press in a new oversize valve seat. When pressing in, the valve seat must be at room temperature.
4. After installing a new valve seat, it is necessary to grind the valve. The width of the working chamfer of the valve seat must be within the technical requirements.
Width of the working chamfer of the inlet valve seat:
- 1.8 and 2.0 l engines: 1.1–1.5 mm;
- 1.6L engines: 0.8–1.2 mm.
Width of the working chamfer of the exhaust valve seat: 1.3–1.7 mm
Replacing the valve guide bushing
1. Using tool 09221–22000 A/B, press the valve sleeve out of the cylinder head towards the cylinder block.
2. Place a new oversized valve guide bushing into the cylinder head bore.
3. Using the valve guide installation tool 09221–22000 A/B, press the guide into the cylinder head. The device ensures pressing of the bushing to a strictly defined depth. Measure the protrusion of the top of the valve guide from the cylinder head. Please note that the valve guide protrusion is different for intake and exhaust valves.
4. After pressing in the valve guides, insert the new valves and check the clearance.
5. Each time the valve guides are replaced, check and, if necessary, replace the valve seats.
Increased valve guide dimensions
Increased dimensions | Size mark | Cylinder head bore diameter |
0,05 | 5 | 11,050–11,068 |
0,25 | 25 | 11,250–11,268 |
0,5 | 50 | 11,500–11,518 |
Assembly
- 1. Clean all parts before installation.
- 2. Apply a thin layer of motor oil to all sliding surfaces.
[The original text is published on the website: hyundaibook]
1. Install the spring seat. Using special tool 09222–22001, install the oil seal.
- 1. Do not reuse old valve stem seals.
- 2. Incorrect installation of the oil deflector cap adversely affects its working edge due to eccentricity and leads to leakage of engine oil through the valve guide bushings.
When installing, be careful not to twist the oil seal.
2. Lubricate the valve stem with engine oil and install the valve. When installing the valve, do not apply too much force to avoid damaging the oil seal. Check the smooth movement of the valve.
3. Install the springs and spring retainers. The springs must be installed with the enamel side facing the spring holders.
4. Using special tool 09222 – 28000, 09222–28100, compress the spring. Install the crackers and remove the special spring compressor.
Caution: When compressing the spring, make sure that the oil seal is not pinched by the spring compressor.
5. Clean all mating surfaces of the cylinder block and cylinder head.
6. Check for markings on the cylinder head gasket.
7. Install the new cylinder head gasket with the marked surface facing the cylinder head.
8. Tighten the cylinder head bolts in the sequence shown in the figure.
Tightening torque of cylinder head mounting bolts for 1.8 and 2.0 l engines:
- M10: 25 Nm, tighten to an angle of 60–65°, tighten to an angle of 60–65°
- M12: 30 Nm, tighten to an angle of 60–65°, tighten to an angle of 60–65°
Tightening torque of cylinder head mounting bolts for 1.6 l engines:
- 30 Nm tighten further at an angle of 90° loosen all bolts 30 Nm tighten further at an angle of 90°