Kia 241002G000 Camshaft Assembly-Intake

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As for the camshafts, they must be inspected scrupulously before the part is to be installed, whereas, camshaft endplay should be measured before the removal of the part. Start with the removal of the cable from the negative terminal of the battery and positioning of the engine at TDC for the number 1 cylinder with the timing marks in line. Next, take off the valve cover,paint the timing belt and camshaft sprockets if they will be aligned later on. On the models produced from 2001 to 2006, the timing belt must be disconnected from the camshaft sprockets while noting its alignment; On all 2006.5- year models, the timing chain must be removed. Ensure the camshaft does not rotate during this time as you remove the sprocket bolts, next measure the end-play of the camshaft. Loosen and take out the front camshaft bearing cap next, then all the other caps and the camshafts but it is wise to retain them in order for assembly. Take off the lash adjusters or lifters and examine all the parts for deterioration. When nurturing to remove the camshaft, the end play of the same must be measured using the dial gauge while the bearing surfaces checked for wear or damage. Camshaft bearing journal diameter should be measured and its comparison should be made with the standard provided to find out the oil clearance. Check the height of each camshaft lobe to specification and check the runout to .001 of an inch on a dial indicator. Check hydraulic adjusters or lifters on what extent they have worn out. For installation, apply a thin layer of oil on the lash adjusters or lifters and on the camshaft lobes and then, align the cams and fit it in the cylinder head in the correct position. Place the bearing caps back in and tighten all the bolts evenly, the camshaft oil seal should be replaced if needed. Rub the camshaft sprocket teeth against the timing belt and ensure the match marks are adjacent then fit the camshaft position sensor. Continuation of the remaining part is in the reverse order to the removal part of the installation. A cut-down bucket style lifter is installed for later models from 2006.5 and the appropriate thickness is used to adjust the valve clearance. Open the valve cover and take the engine to TDC to compare the clearance of some values with the help of a feeler gauge. 'Twist' the engine and take the measurement of the remainder of the valves, changing lifters as equivalent to the thickness measurement. It is recommended after the litters and camshafts have been installed, one should check the clearances before removing the valve cover.

Camshafts should always be checked very well before being fitted while endplay of the camshaft should be checked before the removal of the same. Start with the procedure of removing the cable of negative terminal of the battery and engine setting at TDC for No: 1 cylinder. If it is GDI models, first, you have to deal with the engine remove the high pressure fuel pump next, after that, you will have to take off the valve cover. With the TDC marks aligned, put the large wrench on the camshaft and then remove the bolts of the camshaft phaser sprocket but do not take them off completely. Take out the bolt of the service hole in the timing chain cover and it is imperative for one to clean any Loc-tight sealer that may have stuck to the threads if any. For MPI models, there is a special tool to engage with the timing chain tensioner and unlock it, for GDI models the tensioner ratchet should be unlocked using a screwdriver. Remove the front bearing cap, and raise the chain off the sprocket and onto the camshafts; then, unscrew the bolts of the front bearing cap and the upper bearing. Undo the remaining camshaft cap bolts gradually beginning from the outer ones and take off the camshafts from the cylinder head and retain the caps for re-fittingting. Take out the lifters; also ensure that these are in order too. If it is necessary, take off the camshaft phaser sprocket and check all the elements for signs of wear. Previous to the removing of the camshafts, fit the camshaft with a dial indicator to check the end play and observe the condition of the bearing witnesses also. Check the OD of each camshaft bearing journal and the ID of the matching bearings to determine the oil clearance and replace any of them that are beyond the established standards. Take height of the camshaft lobe and also measure the run out on the lobes by using a dial indicator. Scuff each of the lifters in turn. Coating these with the fresh engine oil before reinstalling them in their intended positions ought to be the area where the exhaust camshaft lower bearing will be fitted and the camshaft phaser sprockets. Put on some lubricant for the camshaft lobes and the journals, the camshaft has to be installed with the T.D.C marks in firm sight of each other old camshaft has to go back to where it was. Then put in the upper bearing and the bearing caps and use the right torque to tighten it with a sequence. Position the timing chain over the camshaft sprockets so that it lines up with the phaser sprocket, and fasten the phaser sprocket bolts. For MPI models take out the special tool and check the timing marks; for GDI models take off the tensioner link. Place and fasten a new service hole bolt. For adjustment, you should have the valve cover off and the number one cylinder at TDC on the compression stroke and then using a feeler gauge, check the clearance between the camshaft lobes and the lifters. Turn the engine again and do the same for the other valves; replace the lifters with improper clearances with new ones. Check the thickness of the lifter head then find the right thickness for the replacement. If new lifters and camshafts have been installed, verify clearances, apply installation lubricant to each lash adjuster and replace the lash adjusters to the position they were previously in. Position each camshaft back to their original position and align the timing marks and then install each bearing caps in a sequential manner and then tightening the bolts to the wished torque.

Before now, to change the engine, set it to TDC position for cylinder number 1 and unbolt the wire of the bad connection from the terminal of the battery before unbolting the valve cover. For year 1994 to 1997 models, take off the distributor and for the models of the year 1998 and above, take off the camshaft position sensor. Then, remove all the timing belt covers, timing belt and all or some of the camshaft sprockets depending on the design. Check the camshaft thrust clearance with a dial indicator; if the same is higher than the above mentioned limit, then replace the camshaft thrust plate, camshaft, or cylinder head may be required. As for further remarks referring to the 1.6L SOHC engines, it is necessary to make the following notes: The 1.6L SOHC engines use the rocker shaft and equipment called hydraulic lash adjusters, which helps avoid additional movements of valves after their installation. Paint or label components before they are taken off so that they can be refitted correctly, counter-clockwise torque the rocker arm bolts, then pull out the rocker arm and shaft assembly and set them aside. To pull the camshaft without involving the cylinder head, you need to remove the distributor, the air cleaner assembly, reposition the under hood fuse box and then pull it straight up to extract it / remove the oil seal. For DOHC engines, these use two overhead camshafts with hydraulic lash adjusters; marking and storage of the parts should be done correctly. The camshaft sprocket bolts and sprockets should be taken off. Disconnect the camshaft bearing cap bolts with equal delicacy so that there will be no binding. Providing identification marks, undo the bearing caps and draw out every valve lash adjuster and place them in different numbers of containers. Look for defects on all parts, use micrometer to measure the camshaft journals, and lobes, and check for the oil clearance by using Plastigage. Replace any worn components. To install the new camshaft, one should pour some clean engine oil on the new camshaft oil seal and the bearing journals and lubricate the camshaft lobes before fitting the camshaft and the thrust plate. Were hydraulic lash adjusters eliminated, refill the rocker arm cavity with oil and then reinsert the adjusters. Reassembly the rocker arm assembly, tighten the bolt in sequential numbers, then the camshaft sprocket and timing belt should be put back. For the 2.0L DOHC engine, carry out the following before and after installation of the camshaft and lash adjusters, lubricate the lash adjusters and the bearing journals of the camshaft. Ensure that the Mark 'A' aligns with mark 'A' when assembling the engine. Lash adjusters are available to adjust the valve clearances and the thickness of the shims must be measured so that it can be replaced by the new one with the standard specifications. Do the adjustment again and again until the clearances of other valves are within the predetermined level.

Install the bearing caps in numerical order with arrows pointing toward the drivebelt end of the engine, tightening the bolts in 1/4-turn increments, starting with the center cap and working outward.

Remove the valve covers, timing chain or belt, and camshaft sprockets.

If necessary, install a new camshaft oil seal and then reinstall the remaining components in reverse order of removal.