Cylinder head cover

Components and Component Location

Components

Repair Procedures

Removal

Be careful not to damage parts located under the vehicle (floor under cover, fuel filter, fuel tank, and canister) when lifting the vehicle with a lift. (Refer to General Information - Jack Lifting Points and Support Points)

Use fender covers to avoid damaging painted surfaces. To prevent damage to the cylinder head, wait until the engine coolant temperature drops below normal temperature (20 °C [68°F]) before removing it. When handling the metal gasket, be careful not to bend the gasket or damage the gasket contact surface. To prevent damage, carefully disconnect the wiring connectors while holding the connector housing.

Label all wires and hoses to avoid incorrect connection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. 1
   Remove the air duct. (Refer to Intake and Exhaust System - Air Cleaner)
2. 2
   Remove the battery. (Refer to Engine Electrical System - "Battery")
3. 3
   Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")
4. 4
   Remove the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
5. 5
   Remove the engine cover. (Refer to Engine and Transaxle Assembly - Engine Cover)
6. 6
   Drain the engine coolant. (Refer to Cooling System - "Engine Coolant")
7. 7
   Disconnect the upper radiator hose (A).

   

8. 8
   Disconnect the radiator lower hose (A).

   

9. 9
   Remove the expansion tank. (Refer to Intake and Exhaust System - "Expansion Tank")
10. 10
    Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
11. 11
    Remove the right exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
12. 12
    Remove the right cylinder head cover. (Refer to Cylinder Head Assembly - Cylinder Head Cover)
13. 13
    Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
14. 14
    Remove the water temperature control unit. (Refer to Cooling System - "Water Temperature Control Assembly")
15. 15
    Remove the right camshaft. (See Cylinder Head Assembly - CVVT and Camshaft)
16. 16
    Remove the delivery pipe. (See Engine Control/Fuel System - Delivery Pipe)
17. 17
    Remove the right cylinder head.

    1. Remove the rear bolt of the right cylinder head (A).

       

    2. Evenly loosen and remove the cylinder head bolts in several passes, in the order shown.

       

       Removing the bolts in the wrong order may cause cylinder head distortion or cracking.

    3. Lift the right cylinder head (A) off the dowels on the cylinder block and place the cylinder head on wooden blocks on the workbench.

       

       Be careful not to damage the mating surfaces of the cylinder head and cylinder block.

    4. Remove the right cylinder head gasket.

       

18. 18
    Remove the air duct. (Refer to Intake and Exhaust System - Air Cleaner)
19. 19
    Remove the battery. (Refer to Engine Electrical System - "Battery")
20. 20
    Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")
21. 21
    Remove the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
22. 22
    Remove the engine cover. (Refer to Engine and Transaxle Assembly - Engine Cover)
23. 23
    Drain the engine coolant. (Refer to Cooling System - "Engine Coolant")
24. 24
    Disconnect the upper radiator hose (A).

    

25. 25
    Disconnect the radiator lower hose (A).

    

26. 26
    Remove the expansion tank. (Refer to Intake and Exhaust System - "Expansion Tank")
27. 27
    Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
28. 28
    Remove the left exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
29. 29
    Remove the generator. (Refer to Engine Electrical System - "Generator")
30. 30
    Remove the left cylinder head cover. (Refer to Cylinder Head Assembly – "Cylinder Head Cover")
31. 31
    Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
32. 32
    Remove the water temperature control unit. (Refer to Cooling System - "Water Temperature Control Assembly")
33. 33
    Remove the left camshaft. (See Cylinder Head Assembly - CVVT and Camshaft)
34. 34
    Remove the delivery pipe. (See Engine Control/Fuel System - Delivery Pipe)
35. 35
    Remove the left cylinder head.

    1. Evenly loosen and remove the cylinder head bolts in several passes, in the order shown.

       

       Removing the bolts in the wrong order may cause cylinder head distortion or cracking.

    2. Lift the left cylinder head (A) off the dowels on the cylinder block and place the cylinder head on wooden blocks on the workbench.

       

       Be careful not to damage the mating surfaces of the cylinder head and cylinder block.

    3. Remove the left cylinder head gasket.

       

Disassembly

Identify the MLAs, valves and valve springs as they are removed so that each component can be reinstalled in its original position.

1. 1
   Remove the MLA (A).

   

2. 2
   Remove the valves.

   1. Using the SST (09222-3K000, 09222-3K100), compress the valve spring and remove the lock retainers.

      

   2. Remove the spring retainer.
   3. Remove the valve spring.
   4. Remove the valve.
   5. Using SST (09222-29000), remove the valve stem seal.

      

   Do not reuse the old valve stem oil seals.

Inspection

1. 1
   Inspect for flatness. Using a precision straightedge and feeler gauge, measure the warpage of the surface contacting the cylinder block. Cylinder head gasket surface flatness Standard: Less than 0.05 mm (0.002 in.) [Less than 0.02 mm (0.0008 in.) / 150x150] Manifold gasket surface flatness Standard: Less than 0.01 mm (0.004 in.) / 110x110

   

2. 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. 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 Intake/Exhaust: 5.500–5.512 mm (0.216–0.217 in.)

      

   2. Using a micrometer, measure the diameter of the valve stem. Valve stem O.D. Intake: 5.465–5.480 mm (0.2151–0.2157 in.) Exhaust: 5.458–5.470 mm (0.2149–0.2153 in.)

      

   3. Subtract the valve stem diameter from the valve guide inside diameter. Stem-to-guide clearance [Standard] Intake: 0.020–0.047 mm (0.0008–0.0018 in.) Exhaust: 0.030–0.054 mm (0.0012–0.0021 in.)
4. 4
   Inspect the valves.

   1. Make sure the valve face is ground to the correct valve face angle.
   2. Check the valve face for wear. If the valve face is worn, replace the valve.
   3. Check the valve head margin thickness. If the margin thickness is less than specified, replace the valve.

      Margin thickness [Standard] Intake: 1.0 mm (0.0394 in.) Exhaust: 1.1 mm (0.0433 in.)

      

   4. Check the valve length.

      Length Intake: 105.27 mm (4.1445 in) Exhaust: 105.50 mm (4.1535 in)

   5. Check the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
5. 5
   Inspect the valve seats. Check the valve seat for signs of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head. Before reconditioning the valve seat, check the valve guide for wear. If the valve guide is worn, replace the cylinder head. Recondition the valve seat using a valve seat grinder or valve seat cutter. The valve seat contact width must be within specification and centered on the valve face.
6. 6
   Inspect the valve springs.

   1. Using a steel square, measure the valve spring squareness.
   2. Using a vernier caliper, measure the valve spring free length. Valve spring [Standard] Free height: 45.5 mm (1.7913 in.) Out-of-square: 1.5°

      

7. 7
   Inspect the MLA. Using a micrometer, measure the outside diameter of the MLA.

   MLA O.D. Intake/Exhaust: 34.964–34.980 mm (1.3765–1.3771 in.)

8. 8
   Using a caliper gauge, measure the inside diameter of the MLA bore in the cylinder head. MLA bore inside diameter Intake/Exhaust: 35.000–35.025 mm (1.3779–1.3789 in.)
9. 9
   Subtract the MLA outside diameter from the MLA bore inside diameter. MLA-to-bore clearance [Standard] Intake/Exhaust: 0.020–0.061 mm (0.0008–0.0024 in.)

Installation

Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace the oil seals with new ones.

1. 1
   Install the valves.

   1. Using SST (09222-3C100), install a new oil seal.

      Do not reuse the old valve stem oil seals. Incorrect seal installation may cause oil to leak past the valve guides.

      

   2. Install the valve, valve spring and spring seat.

      Install the valve springs so that the side with the paint faces the valve spring retainer, then install the lock retainers.

   3. Using the SST (09222-3K000, 09222-3K100), compress the spring and install the lock retainers. After installing the valves, make sure the lock retainers are seated before releasing the valve spring compressor.

      

   4. Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve and lock retainer.
2. 2
   Install the MLA (A). Check by hand that the MLA rotates smoothly.

   

   The MLAs can be reinstalled in their original positions. However, the valve clearance must be rechecked and adjusted accordingly before the cylinder head is installed on the cylinder block. See the general information in the EM section for the valve clearance inspection and adjustment procedure.

Installation

Thoroughly clean all parts to be assembled. Always use a new cylinder head gasket and manifold gasket. Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to permanently stretch beyond their elastic limit when tightened, so if the bolts are removed and reused, they may break or lose clamping force. The cylinder head gasket is a metal gasket. Be careful not to bend it. Rotate the crankshaft and set the No. 1 piston to top dead center.

1. 1
   Install the right cylinder head.

   a.	The sealant application areas on the cylinder head and cylinder block must be free of engine oil and ETC.

   b.

   Before assembly, apply TB 1217H sealant to the upper surface of the cylinder block. Assemble the part within 5 minutes after applying the sealant. Apply the sealant as shown in the following illustration. Bead width: 2.0–3.0 mm (0.078–0.118 in.) Sealant application points: 1.0–1.5 mm (0.039–0.059 in.) from the block surface Recommended sealant: TB 1217H Liquid sealant

   b.	Apply TB 1217H sealant to the cylinder head gaskets after installing them on the cylinder block. Assemble the part within 5 minutes after applying the sealant. Make sure to observe the correct installation direction.

   d.	Install the right cylinder head (A). Remove any squeezed-out sealant after assembling the cylinder head.

2. 2
   Install the right cylinder head bolts.

   1. Do not apply engine oil to the threads or under the heads of the cylinder head bolts.
   2. Install and tighten the cylinder head bolts and the plate washers in several steps, in the specified sequence.

      Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts, designed to be permanently stretched beyond the elastic limit when tightened. If the bolts are removed and reused, they may break or fail to maintain clamping force.

      Tightening torque: Cylinder head bolt: 37.3–41 N·m N·m + (118 - 122°) + (88 - 92°) Bolt (A): 18.6–24 N·m N·m

      

      

3. 3
   Install the remaining parts in the reverse order of removal.

   Fill the engine oil. Clean the battery terminal posts and cable clamps with sandpaper. Assemble, then apply grease to prevent corrosion. Inspect for fuel leaks. After assembling the fuel line, turn the ignition switch ON (do not start the engine) to operate the fuel pump for about 2 seconds and pressurize the fuel line. Repeat this operation two or three times, then check for fuel leaks at all points of the fuel line. Fill the radiator and the coolant reservoir with engine coolant. Bleed air from the cooling system. Start the engine and let it run until it warms up (until the radiator fan cycles 3-4 times). Stop the engine and let it cool down. Check the coolant level in the radiator and add coolant if necessary. This will allow trapped air to be bled from the cooling system. Securely install the radiator cap, then restart the engine and check for leaks.

4. 4
   Install the left cylinder head.

   a.	The sealant application areas on the cylinder head and cylinder block must be free of engine oil and ETC.

   b.

   Before assembly, apply TB 1217H sealant to the upper surface of the cylinder block. Assemble the part within 5 minutes after applying the sealant. Apply the sealant as shown in the following illustration. Bead width: 2.0–3.0 mm (0.078–0.118 in) Sealant application points: 1.0–1.5 mm (0.039–0.059 in) from the block surface Recommended sealant: TB 1217H (Hyundai Grey RTV) liquid sealant

   b.	Apply TB 1217H sealant to the cylinder head gaskets after installing them on the cylinder block. Assemble the part within 5 minutes after applying the sealant. Make sure to observe the correct installation direction.

   d.	Install the LH cylinder head (A). Remove any squeezed-out sealant after assembling the cylinder head.

5. 5
   Install the left cylinder head bolts.

   1. Do not apply engine oil to the threads or under the heads of the cylinder head bolts.
   2. Install and tighten the cylinder head bolts and the plate washers in several steps, in the specified sequence.

      Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts, designed to be permanently stretched beyond the elastic limit when tightened. If the bolts are removed and reused, they may break or fail to maintain clamping force.

      Tightening torque: Cylinder head bolt: 37.3–41 N·m N·m + (118 - 122°) + (88 - 92°)

      

6. 6
   Install the remaining parts in the reverse order of removal.

   Fill the engine oil. Clean the battery terminal posts and cable clamps with sandpaper. Assemble, then apply grease to prevent corrosion. Inspect for fuel leaks. After assembling the fuel line, turn the ignition switch ON (do not start the engine) to operate the fuel pump for about 2 seconds and pressurize the fuel line. Repeat this operation two or three times, then check for fuel leaks at all points of the fuel line. Fill the radiator and the coolant reservoir with engine coolant. Bleed air from the cooling system. Start the engine and let it run until it warms up (until the radiator fan cycles 3-4 times). Stop the engine and let it cool down. Check the coolant level in the radiator and add coolant if necessary. This will allow trapped air to be bled from the cooling system. Securely install the radiator cap, then restart the engine and check for leaks.