I would go with your instinct and not the picture. Usually diagrams like these are more universal, and you will find small changes here and there. If you got to your crackshaft, you have enough skill to use your judgement over that type of diagram discrepancy.

 

I just did a valve job on my son's 2008 Hyundai Accent 1.6L (same as the RIO's)... The CVT on the intake cam and the exhaust cam have markings on the other side (inside the engine) and if you reverse the image you have (look at the other side of both cams) you will see them... Also look at the first two cam lobes moving away from the chain...They point at each other --> <-- ... The chain has two black links that the markings should be on... Be careful with the chain tensioner in the center as it is plastic and can break and torque the bolts as per the KIA/Hyundai engine manual... Keep the chain taut at the bottom and the slack at the top.... The tension spring broke on his 1.6L and all 8 intake valves were bent...I replaced the valves and lapped them to the head's valve seats and the engine runs fine... Use a new head gasket, valve cover, and exhaust gasket and you're good to go...
Dave

 

Camshaft chain position

half of the cylinder head bolts (on the exhaust side) are placed in a very bad location.....underneath the camshaft.....so exhaust camshaft needs to be removed to get to them.....this creates a possibility to make a mistake when aligning the chain

Just wondering, is this Kia/Hyundai "special" design, or others build engines like this ?

Diagram turned out to be totally useless because of confusing marks on both side of sprockets.

At the end I just used a common sense approach:
Put Cyl1 to TDC (hole on exhaust camshaft lined up with red dot, then made Cyl1 intake and exhaust rocker arm's lobes to same height (by measuring the distance from the tip of lobes to rocker arm holder.

The spring tensioner also a "special" device.....spring inside, and oil flows through some small holes.... it acts as cylinder with some delays
The top part holds the chain at a fixed distance, the bottom part applies tension.
Broken spring = bad quality spring !

My problem started with a broken woodruff (retainer clip) on the crankshaft's, keeping timing belt pulley in position......resulted bent valves !

Thank you for all the replies!

 

Other small Asian cars do this. and some old VWs. I have not played with enough small stuff other than these to confirm, but its not just Hyundai.

 

Jenom...
You should be glad to hear that these "interference" type engines DO survive to run another day... (usually without a major head job)...
I did buy a special valve retainer removal tool that looks like a large center punch...I made removing and re-installing the valves EASY...
Proper torquing is MANDATORY with the aluminum heads...
I hope you DID lap the valves to the valve seats...as this is a MAJOR boo boo for first time valve jobs... They will not seat properly and you will have low compression (if any)...

On my son's 1.6L the timing belt tensioner spring broke allowing the timing belt to get torn up (had 5k on that belt) and the mechanical timing to slip...
With my labor (free) and parts from rockauto.com we got his back on the road for under $300...
Glad it wasn't a 2.0L used in the Elantras and Spectras as they really self destruct with valves going through the top of the pistons...
I have seen two of the 1.6L with just bent intake valves....
Keep us posted on your outcome...
Dave

 

Camshaft chain position--P0016 P0016 - Crankshaft Position - Camshaft Position Correl

Engine seems to running fine, maybe a little bit noticable of power loss, however getting Check Engine Light on, and Scantool shows P0016 - Crankshaft Position - Camshaft Position Correlation

Did a research about this error: --The computer counting signal pulses from cranckshaft sensor and camshaft sensor ....if does not match with ideal settings.....ERROR P0016 !

It is easy to be off 1 tooth on timing belt, so I have re-done timing belt to be sure it is on the marks between the crankshaft and camshaft (exhaust camshaft).....still getting same error !

However, since the camshaft sensor is on top of the intake camshaft, now I suspect the misalignment of the CHAIN between them.

Unfortunately, for the CHAIN alignment I found 3 instructions( see attached pictures) and they are different:

Instruction #1 marks are far on the sides, exhaust cam around 9 am, intake cam around 3 pm
Instruction #2 marks are on top/close to top , 4 chain links between
Instruction #3 marks are on top/close to top, 5 chain linsk between

I think, the best help would be, if someone can tell me, what should I see when at TDC and I look down into the hole of the camshaft sensor....where is the position of that signal sender?
Camshaft sensor comes out very easy, just one 10 mm bolt, than twist and lift.
(see attached picture of camshaft signal sender )

Any suggestions will be appreciated !

 

The correct position, for cvvt G4ED engine, is the first picture that you posted. The markers are easy to see, then you can not miss. If obd report P0016 your engine is out of phase! Please post a picture of the other side (passenger-right) of the cam. This is mine:

You can see, with the timing belt camshaft sprocket marker in position (the little hole centered on the cylinder head marker), on the other cam there is an hole that must be in the same position:

PAY ATTENTION: MY VERSION IS 1.4 WITHOUT CVVT, so i can not guarantee that in 1.6 the position is the same, but as far as I know the position on right side marker does not change from 1.4 to 1.6. In any case use the markers on the cams and chain, also without a schema are evident to see on both and, above all, do not start the engine if you are not 100% sure, or you could do damage. These are interference engines!

 

camshaft chain position

thank you for "blkid" for the reply and the pictures

meanwhile, I used my "spare" cylinder head (bent valves ) to figure things out:

this is when you are looking at things from the driver's side (battery/airfilter)

--two chain link on one-side is painted black--hard to see when it swimming in oil
--the groove on the CVVT drum is one mark
--on the intake chain sprocket there is an arrow/triangle mark just below a teeth

so all I needed to do is :

1) put crankshaft and camshaft to TDC
2) align black chain link's center to CVVT housing mark
3) align the other black chain link's center of intake sprocket arrow mark
there should be 6 chain link between the two black chain links

there are more marks on both chain sprockets on the inner side, just ignore them

used my ELM 327 OBD device and Scantool program to erase P0016, it is gone now!
Thanks for all support and help !

 

thank you for "blkid" for the reply and the pictures

meanwhile, I used my "spare" cylinder head (bent valves ) to figure things out:

this is when you are looking at things from the driver's side (battery/airfilter)

--two chain link on one-side is painted black--hard to see when it swimming in oil
--the groove on the CVVT drum is one mark
--on the intake chain sprocket there is an arrow/triangle mark just below a teeth

so all I needed to do is :

1) put crankshaft and camshaft to TDC
2) align black chain link's center to CVVT housing mark
3) align the other black chain link's center of intake sprocket arrow mark
there should be 6 chain link between the two black chain links

there are more marks on both chain sprockets on the inner side, just ignore them

used my ELM 327 OBD device and Scantool program to erase P0016, it is gone now!
Thanks for all support and help !

If you see your second picture:

The position of cams marker seems good. The chain marker are not phased respect the cams because rotating it lost their position and is normal. If you put the chain in position with their markers on cam markers, the position of both cam is the same. So, on your new cylinder head, use the 2 marker on the cams sprocket, centered on the chain markers and the job is done!

If you can remove the chain from broken cylinder head, post a photo of both side of chain. In one of the 2 side 2 mesh have different color.

Edit: this is the schema of cams part for cvvt version:

Edit 2: OK, seeing better the photo, seems that you have already well positioned markers chain that, compared to my version, are darker (on my chain instead the mesh marker are bronze/gold). I have not read your entire message !!!

 

Camshaft chain position

Thanks for the info and parts list,
few days past now, and all working good, no more error code
here are some more close-up pictures, the " black" chain links are more visible
not sure, what to do with old cylinder head?
it has at least 4 bent valves, is it worth to replace them and sell it or keep it as a spare ?

 

Usually a bent valve also ruin the valve seat (It depends on how much it is bent), then most likely it is also necessary to grind the valve seats. If you bought a new cylinder head, hold by the old as it is, avoiding spending other money. You can reuse the good components as spare parts, hoping that you never need they!

 

Kia/hyundai 1.6L cvvt G4ED camhsaft chain position.

ok, its really easy to get it right, just did it myself.
1st: put the exhaust cam at tdc, there is a small hole in the timing gear and a notch in the outer bearing (outside of head) if those are lined up, your exhaust cam is at tdc. On the side where your chain is, there is a notch located directly above the uppermost tooth on the sprocket.
2nd: on the passenger side of the intake cam, there is a hole on the end of the shaft. make sure its facing up. locate the mark on the back of intake cam (toward the driver side) there is a small arrow on one of the teeth.
3rd: find the two off colored (darker) chain links. Put one of them on the tooth under the notch on the exhaust cam, and one on the tooth with the arrow on the intake cam. there should be 6 links inbetween both marks or counting from one mark to the other 8 total links. there should be slack on top of the chain, and tension on the bottom. The hole on the passenger side of the intake came should still be facing up.