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Hyundai Santa Fe (2006 year). Manual - part 308

EM -34

ENGINE (D4EB - DIESEL 2.2)

WARPAGE

Check the cylinder head(A) for warpage.

• If warpage is less than 0.03mm (0.0012in.)

for

width, 0.09mm (0.0035in.) for length and 0.012mm
(0.0035in) for 51mm ×51mm, cylinder head is in good
condition.

• If warpage is over the standard value, replace the

cylinder head.

ACIE084A

Measure along edges, and three ways across center.

ACIE085A

REASSEMBLY

E75104BF

NOTE

Prior to reassembling, cylinder head assembly shall
be cleaned sufficiently to remove scrap and clust.
(Clean holes with special care.)

Using the SST(09222-27200) insert the valve stem
seals(A).

09222-27200

ACIE086A

Insert the valves through the valve stem seals.

NOTE

Make sure the valves move up and down smoothly.

Install the valve spring(A) and valve spring re-
tainer(B), then install the SST (09222-27300, the
valve spring compressor). Compress the spring(A)
and install the valve spring retainer lock(c).

09222-27300

ACIE087A

CYLINDER HEAD ASSEMBLY

EM -35

Lightly tap the end of each valve stem two or three
times with a plastic mallet to ensure proper seating of
the valve and valve spring retainer locks.

NOTE

Tap the valve stem only along its axis so you do not
bend the stem.

Assembly of lash adjuster.
a.

Until installing, lash adjuster shall be held upright
so that gas oil in lash adjuster should not spill and
assured that dust does not adhere to adjuster.

Lash adjust shall be inserted tenderly to the cylin-
der head not to spill gas oil from lash adjuster. In
case of spilling air bent shall be done in accor-
dance with the air bent procedure below.

NOTE

Air bent procedure
1.

In case of lash adjuster alone.
Stroke lash adjuster in gas oil 4~5 times by push-
ing its cap while pushing the ball down slightly by
hard steel wire.
Take care not to severely push hard steel wire
down since ball is several grams.

After installed on engine
Lash adjuster might give out unusual noise if air is
mingled. Apply slow racing from idle to 3,000rpm
(Approximately one minute per one racing) and
the air shall be removed from adjuster.
Therefore noise can be extinguished.

Install the valve-caps.

Put the cam followers on the lash adjusters and valve
caps.

After wiping down the camshaft and camshaft seal in
the cylinder head, lubricate both surfaces and install
the camshaft with engine oil.

Confirm that cam followers are located on lash ad-
justers and their rollers are in touch with camshaft.

10. In assembly camshaft bearing cap, to the cylinder

head with the cylinder block, all pistons should be in
the middle position between TDC(Top Dead Center)
and BDC(Bottom ead Center) because valves come
out of the bottom surface of the cylinder head.

11. Install the bolts loosely.

12. Tighten each bolt two turns at a time in the sequence

shown below to ensure that the cam followers do not
bind on the valves.

Tightening torque
26.5 ~ 29.5N.m (2.65 ~ 2.95kgf.m, 20 ~ 22lb-ft)

10 6 2 3 7 11

9 5 1 4 8 12

ACIE073A

EM -36

ENGINE (D4EB - DIESEL 2.2)

INSTALLATION

E4F40791

Install the cylinder head in the reverse order of removal :

NOTE

• Always use a new head gasket.
• Cylinder head and cylinder block surface must be

clean.

• Turn the crankshaft so the No.1 piston is at

TDC(Top Dead Center).

Cylinder head dowel pins must be aligned.

Select the cylinder head gasket.
a.

Measure the piston protrusion from the upper
cylinder block face (I) on 8 places (A ~ H) at T.D.C.
Measure on the crankshaft center line consider-
ing the piston migration.

H G F E D C B A

ACIE088A

ACIE089A

Select the gasket in the table below using the
average value of piston protrusions.
Although even the only 1 point is over than the
each rank limit, use 1 rank upper gasket than
specified in the table below.

ACIE090A

Displacement

2.2 L

Average of pisston
protrusion

0.194 ~ 0.337mm (0.0079

~ 0.013in.)

0.337 ~ 0.440mm (0.013

~ 0.017in.)

0.440 ~ 0.542mm (0.017

~ 0.021in.)

Gasket thickness

1.1 ± 0.05mm (0.0433

± 0.0020in.)

1.2 ± 0.05mm (0.0472

± 0.0020in.)

1.3 ± 0.05mm (0.0512

± 0.0020in.)

Limit of each rank extant

0.43mm (0.0169in.)

0.53mm (0.0208in.)

Identification code

SCMEM6102D

SCMEM6103D

SCMEM6104D

c. Install the gasket so that the identification mark
faces toward the flywheel side.

CYLINDER HEAD ASSEMBLY

EM -37

Position the cylinder head assembly over the gasket.

Tighten the cylinder head bolts slightly.

Install the camshaft sprocket, aligning the timing
mark.

Tightening torque
122.6 ~ 137.3N.m (12.5 ~ 14.0kgf.m, 90.4 ~ 101.3lb-ft)

Tighten the bolts to the specified torque

Tightening torque
63.7N.m (6.5kgf.m, 47.0lb-ft) + 120 + 120

9 5 1 4 8

10 6 2 3 7

ACIE094A

NOTE

• Tightening sequence of cylinder head bolt should

be confirmed to the upper drawing.

• Cylinder head bolt must be replaced.

Install the fuel pump assembly.

Install the intake/exhaust manifold assemblies.

Install the hose between the vacuum pump and the
cylinder head.

10. If it is necessary to replace the oil seals on the cylinder

head cover for injectors, use the SST(09351-27401).

11. Install the head cover gasket in the groove of the cylin-

der head cover.

NOTE

• Cylinder head cover gasket must be replaced.
• Before installing the head cover gasket, throughly

clean the seal and the groove.

• When installing, make sure the head cover gas-

ket is seated securely in the corners of the re-
cesses with no gap.

12. Apply liquid gasket to the head cover gasket at the

four corners of the recesses.

NOTE

• Use liquid gasket LOCTITE 5699 or TH1212D.
• Check that the mating surface are clean and dry

before applying liquid gasket.

• Do not install the parts if five minutes or more

have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.

• After assembly, wait at least 30 minutes before

filling the engine with oil.

13. When installing the cylinder head cover, hold the head

cover gasket in the groove by placing your fingers on
the camshaft holder contacting surfaces (top of the
semicircles).
Once the cylinder head cover is on the cylinder head,
slide the cover slightly back and forth to seat the head
cover gasket.

NOTE

• Before installing the cylinder head cover, clean

the cylinder head contacting surfaces with a shop
towel.

• Do not touch the parts where liquid gasket was

applied.

• Take care not to damage the oil seals when in-

stalling the cylinder head cover.

• Visually check the oil seals for damage.
• Replace any washer that is damaged or deterio-

rated.

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