Hyundai Kona Quiz
Engine Mechanical System

Cylinder Head Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
60steps
~375min
5/5difficulty
3special tools
010203040506.95N·mlb·ft
Tightening torque found on this page
Done 0 of 60

Removal

Engine removal is not necessary for this procedure.
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")
  3. Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")
  4. Remove the battery. (Refer to Engine Electrical System - "Battery")
  5. Disconnect the ECM connector, then remove the battery tray. (Refer to Engine Electrical System - Battery)
  6. Remove the battery tray. (Refer to Engine Electrical System - "Battery")
  7. Remove the engine room cover.
  8. Loosen the drain plug and drain the coolant. Open the radiator cap to speed up draining. (Refer to Cooling System - Coolant)
  9. Remove the radiator upper hose (A).
  10. Remove the lower radiator hose (A).
  11. Disconnect the intercooler intake hose and pipe.
    1. Disconnect the intercooler intake hose (A).

      Tightening torque: 4.9–6.9 N·m

    2. Disconnect the intercooler intake hose (A) from the turbocharger and remove the intercooler intake pipe (B). Tightening torque: Clamp: 4.9–6.9 N·m Mounting bolt: 18.6 – 24 N·m
  12. Remove the intercooler outlet hose and tube.
    1. Disconnect the intercooler outlet hose (A).
    2. Disconnect the boost pressure sensor (BPS) connector (B).
    3. Disconnect the RCV solenoid hose (C).
    4. Disconnect the RCV solenoid valve connector (D).

      Tightening torque: 4.9–6.9 N·m

  13. Disconnect the engine wire harness connector and the cable clamp, then remove the cylinder head cover heat shield and the wire harness from the engine.
  14. Disconnect the brake booster vacuum hose (A).
  15. Remove the heater hoses (A).
  16. Remove the vacuum hose assembly (A).
  17. Remove the cylinder head cover. (Refer to Cylinder Head Assembly - Cylinder Head Cover)
  18. Remove the timing chain cover. (See Timing System - "Timing Chain Cover and Oil Pump Assembly")
  19. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  20. Remove the camshaft. (See Cylinder Head Assembly - "CVVT and Camshaft")
  21. Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
  22. Remove the turbo exhaust manifold. (See Intake and Exhaust System - "Exhaust Manifold")
  23. Remove the delivery pipe assembly. (See Fuel System - "Delivery Pipe")
  24. Disconnect the bypass hose, then remove the water temperature control valve assembly. (See Cooling System - "Water Temperature Control Assembly")
  25. Remove the heater tube. (See Cooling System - "Water Temperature Control Assembly")
  26. Remove the intake OCV (oil control valve). (See Fuel System - "CVVT Oil Control Valve")
  27. Remove the rear suspension (A).
  28. Remove the cylinder head cover heat insulator (A).
  29. Remove the cylinder head bolts, then remove the cylinder head.
    1. Loosen and remove the 10 cylinder head bolts evenly in several steps, in the order shown.
    2. Lift the cylinder head off the cylinder block and place the cylinder head on wooden blocks.

Disassembly

  1. Remove the MLA (A).
  2. Remove the valves.
    1. Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove the retainer lock.
    2. Remove the spring retainer.
    3. Remove the spring retainer.
    4. Remove the valve.
    5. Remove the valve stem seal.
    6. Using a magnetic pick-up tool, remove the spring seat.

Inspection

Cylinder head cover

  1. Inspect for flatness. Using a precision straightedge and feeler gauge, measure the cylinder head and manifold contact surfaces for warpage. Cylinder head gasket surface flatness Standard: Overall less than 0.05 mm (0.0020 in.); less than 0.02 mm (0.0008 in.) for a 100 mm (3.9370 in.) x 100 mm (3.9370 in.) section.
  2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If any cracks are found, replace the cylinder head.
  3. Inspect the valve stems and valve guides.
    1. Using a caliper gauge, measure the inside diameter of the valve guide.

      Valve guide inside diameter: 5.500–5.512 mm (0.2165–0.2170 in.)

    2. Using a micrometer, measure the outside diameter of the valve stem. Valve stem outside diameter Intake: 5.465–5.480 mm (0.2152–0.2157 in.) Exhaust: 5.458–5.470 mm (0.2149–0.2154 in.)
    3. Subtract the valve stem outside diameter from the valve guide inside diameter measurement. Valve stem-to-guide clearance Intake: 0.020–0.047 mm (0.0008–0.0019 in.) Exhaust: 0.030–0.054 mm (0.0012–0.0021 in.) If the clearance is greater than specified, replace the valve or the cylinder head.
  4. Inspect the valves.
    1. Make sure the valve face is ground to the correct valve face angle.
    2. Inspect the valve face for wear. If the valve face is worn, replace the valve.
    3. Check the valve head margin thickness. If the margin is less than the minimum, replace the valve. Standard Specification Intake: 1.35–1.65 mm (0.0531–0.0650 in.) Exhaust: 1.55–1.85 mm (0.0610–0.0728 in.)
    4. Check the valve length. Standard valve length Intake: 93.15 mm (3.6673 in.) Exhaust: 92.60 mm (3.6457 in.)
    5. Inspect the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
  5. Inspect the valve seats.
    1. Inspect the valve seat for signs of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.
    2. Inspect the valve guide for wear. If the valve guide is worn, replace the cylinder head.
  6. Inspect the valve springs.
    1. Using a steel square, measure the valve spring squareness.
    2. Using a caliper gauge, measure the free length of the valve spring. Valve spring Standard free height: 45.1 mm (1.7756 in.) Out-of-square: less than 1.5°
Valve and Valve Spring

Installation

  1. Install the valves.
    1. Install the spring seats.
    2. Using SST (09222-2B100), install a new valve stem seal.
    3. Install the valve, valve spring and retainer after applying engine oil to the end of each valve stem.
  2. Using SST (09222-3K000, 09222-3K100), compress the spring and install the retainer lock. After installing the valves, make sure the retainer locks are seated correctly before releasing the valve spring compression.
  3. Lightly tap the end of each valve stem two or three times with a wooden hammer handle to ensure the valve and retainer lock are seated correctly.
  4. Install the MLA (mechanical lash adjuster). Make sure the MLA (A) rotates smoothly by hand.

Installation

  1. Install the cylinder head assembly.
    1. Before installation, remove hardened sealant from the cylinder block and cylinder head surfaces.
    2. Before installing the cylinder head gasket, apply sealant to the upper surface of the cylinder block and install the gasket in place within five minutes.
      Width: 2.0–3.0 mm (0.0787–0.1181 in.) Sealant position: 15 mm from the front side of the cylinder block. Sealant specification: liquid gasket TB1217H or LOCTITE 5900.
    3. After installing the cylinder head gasket on the cylinder block, apply sealant to the upper surface of the cylinder head gasket and assemble within five minutes.
  2. Carefully install the cylinder head so as not to damage the gasket.
  3. Install the cylinder head bolts with washers.
    1. Tighten the 10 cylinder head bolts in several passes in the sequence shown.

      Tightening torque: 29 N·m + 90° + 90°

  4. Install the cylinder head cover heat shield (A).

    Tightening Torque: 9.8–11.8 N·m

  5. Install the rear suspension (A).
  6. Install the oil control valve (OCV). (Refer to Fuel System - "CVVT Oil Control Valve (OCV)").
  7. Install the heater hose tube. (Refer to Cooling System - "Water Temperature Control Assembly")
  8. Install the humidity control unit and bypass hose. (Refer to Cooling System - "Water Control Assembly")
  9. Install the delivery pipe assembly. (Refer to Fuel System - "Delivery Pipe")
  10. Install the turbo manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  11. Install the intake manifold. (Refer to Air Intake and Exhaust System - "Intake Manifold").
  12. Install the camshaft. (Refer to Cylinder Head Assembly - "CVVT and Camshaft")
  13. Install the timing chain. (Refer to Timing System - Timing Chain)
  14. Install the timing chain cover. (Refer to Timing System - "Timing Chain Cover and Oil Pump Assembly")
  15. Install the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")
  16. Install the vacuum hose assembly (A).

    Tightening Torque: 9.8–11.8 N·m

  17. Connect the heater hose (A).
  18. Connect the vacuum brake hose (A).
  19. Install in the reverse order of removal.

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