Engine Repair procedures – Hyundai Sonata 2012 > 2.4

2012 > G 2.4 DOHC > G 2.4 DOHC > Engine Mechanical System > General Information > Repair procedures

Inspection
Compression Pressure Inspection
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1.
Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2.
Disconnect the injector connectors (A) and ignition coil connectors (B).

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3.
Remove ignition coils(A).

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4.
Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.
5.
Check cylinder compression pressure.
a.
Insert a compression gauge into the spark plug hole.

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b.
Fully open the throttle.
c.
While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 200 rpm or more.
d.
Repeat steps (a) through (c) for each cylinder.
This measurement must be done in as short a time as possible.

Compression pressure :
1,283kPa (13.0kgf/cm², 185psi)
Minimum pressure :
1,135kPa (11.5kgf/cm², 164psi)
Difference between each cylinder :
100kPa (1.0kgf/cm², 15psi) or less

e.
If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
6.
Reinstall spark plugs.
7.
Install ignition coils.
8.
Connect the injector connectors and ignition coil connectors.
Valve Clearance Inspection And Adjustment
Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C (68°F)) and cylinder head is installed on the cylinder block.
1.
Remove the engine cover(A).

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2.
Remove the cylinder head cover.
a.
Disconnect the ignition coil connectors(A) and remove the ignition coils.

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b.
Disconnect the P.C.V hose(A).

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c.
Disconnect the breather hose (A).

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d.
Loosen the cylinder head cover bolts and then remove the cover(A) and gasket.

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3.
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 camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°)

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4.
Inspect the valve clearance.
a.
Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

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·Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
·Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting tappet.

Valve clearance
Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)

b.
Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark “T” of the lower timing chain cover.
c.
Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance.

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5.
Adjust the intake and exhaust valve clearance.
a.
Set the No.1 cylinder to the TDC/compression.
b.
Marks on the timing chain and camshaft timing sprockets.
c.
Remove the service hole bolt(A) of the timing chain cover.

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The bolt must not be reused once it has been assembled.
d.
Insert the SST(A) (09240-2G000) in the service hole of the timing chain cover and release the ratchet.

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e.
Remove the front camshaft bearing cap(A).

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f.
Remove the exhaust camshaft bearing cap and exhaust camshaft.
g.
Remove the intake camshaft bearing cap and intake camshaft.
When disconnect the timing chain from the camshaft timing sprocket, hold the timing chain.
h.
Tie down timing chain so that it dosen’t move.
Be careful not to drop anything inside timing chain cover.
i.
Measure the thickness of the removed tappet using a micrometer.

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j.
Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

Valve clearance (Engine coolant temperature : 20°C)
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A – 0.20mm(0.0079in.)]
Exhaust : N = T + [A-0.30mm (0.0118in.)]

k.
Select a new tappet with a thickness as close as possible to the calculated value.
Shims are available in 47size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.690mm (0.1452in.)
l.
Place a new tappet on the cylinder head.
m.
Hold the timing chain, and install the intake camshaft and timing sprocket assembly.
n.
Align the matchmarks on the timing chain and camshaft timing sprocket.
o.
Install the intake and exhaust camshaft.
p.
Install the front bearing cap.
q.
Install the sevice hole bolt.

Tightening torque :
11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)

r.
Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and camshaft sprocket timing marks(A).

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s.
Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C)
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)