Hyundai Tucson LM Quiz
Engine Mechanical System

Cylinder Head Repair Procedures

In this manual: Engine Mechanical System
General Information — 1Engine Mechanical System — 44Engine Electrical System — 45Emission Control System — 24Engine Control System/Fuel System — 93Clutch System — 13Manual Transmission — 18Automatic Transmission — 87Four-Wheel Drive (4WD) System — 26Drive Shaft and Axle — 29Suspension System — 35Steering — 20Restraints — 47Brake System — 36Body (Interior and Exterior) — 53Body Electrical System — 202Heating, Ventilation, and Air Conditioning — 58
75steps
~470min
5/5difficulty
4special tools
0102030405013.710N·mlb·ft
Tightening torque found on this page
Done 0 of 75

Removal

Engine removal is not necessary for this procedure.
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging 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 avoid damage, carefully disconnect the wiring connectors by holding the connector body.
  • Label all wires and hoses to avoid incorrect connection.
  • Turn the crankshaft pulley so that the No. 1 piston is at TDC (top dead center).
  1. Disconnect the negative battery terminal. (Refer to Engine and Transaxle Assembly in this group)
  2. Remove the right front wheel. (Refer to Suspension System - "Wheel")
  3. Remove the under cover. (Refer to Engine and Transaxle Assembly in this group)
  4. Remove the engine cover. (Refer to Engine and Transaxle Assembly in this group)
  5. Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System in this group)
  6. Loosen the drain plug and drain the engine coolant. Remove the radiator cap to drain the coolant faster. (Refer to Cooling System in this group)
  7. Disconnect the upper radiator hose and lower hose. (Refer to Cooling System in this group)
  8. Disconnect the wiring connectors and harness clips, then remove the wiring and protector from the cylinder head and intake manifold.
    1. OCV (Oil Control Valve) Intake Connector (A)
    2. OCV (Oil Control Valve) Exhaust Connector (A)
    3. Alternator Connector (A)
    4. Ignition coil connectors (A)
    5. Fuel pump connector (B)
    6. CMPS (Camshaft Position Sensor) Intake Connector (A)
    7. CMPS (Camshaft Position Sensor) Exhaust Connector (B)
    8. Injector Extension Connector (A)
    9. Front HO2S (Heated Oxygen Sensor) Connector (A)
    10. Condenser Connector (A)
    11. PCSV (Purge Control Solenoid Valve) Connector (A)
    12. ECTS (Engine Coolant Temperature Sensor) Connector (A)
    13. VIS (Variable Intake System) Connector (A)
    14. MAPS (Manifold Absolute Pressure Sensor) and IATS (Intake Air Temperature Sensor) Connector (A)
    15. ETC (Electronic Throttle Control) Connector (A)
  9. Disconnect the heater hoses (A).
  10. Disconnect the fuel hose (A) and PCSV (Purge Control Solenoid Valve) hose (B).
  11. Remove the intake and exhaust manifolds. (Refer to Intake and Exhaust System in this group)
  12. Remove the timing chain drive, including the drive belt, cylinder head cover, generator, and timing chain cover. (Refer to Timing System in this group)
  13. Remove the injector insulator (A).
  14. Remove the injector and fuel rail assembly (A). (Refer to Engine Control/Fuel System - "Injector")
  15. Remove the vacuum hose (A).
  16. Remove the high-pressure pipe (A) and PCSV (Purge Control Solenoid Valve) bracket (B). (Refer to Engine Control System/Fuel System - "High Pressure Fuel Pump")
  17. Remove the condenser (A).
  18. Remove the fuel pump adapter assembly (A).
  19. Remove the intake CVVT assembly (A) and the exhaust CVVT assembly (B).
    When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent it from rotating.
  20. Remove the camshaft.
    1. Remove the camshaft bearing cap (A) by loosening the bolts in the specified sequence.
    2. Remove the camshafts (A).
  21. Remove the cam holder (A).
  22. Remove the HLA (Hydraulic Lash Adjuster) (A) and rocker arm (B).
    The HLA and rocker arm must be stored together as pairs after removal and during reinstallation.
  23. Disconnect the bypass hose (A).
  24. Loosen the heater pipe mounting bolts (B).
  25. Remove the water temperature control unit. (Refer to Cooling System in this group)
  26. Remove the oil control adapter (A) with the gasket (B).
  27. Remove the intake OCV (oil control valve) (A).
  28. Remove the exhaust OCV (oil control valve) (A).
  29. Remove the rear engine mounting bracket (A).
  30. Remove the spark plugs (A). (Refer to Engine Electrical System - "Ignition System")
  31. Remove the cylinder head.
    1. Using a torx socket (12 point), loosen and remove the cylinder head bolts evenly in several passes in the specified sequence.
      Cylinder head distortion or cracking may result if the bolts are loosened in the wrong order.
    2. Lift the 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 contact surfaces of the cylinder head and cylinder block.
    3. Remove the cylinder head gasket (B).

Disassembly
Identify the valves and valve springs as they are removed so that each part can be reinstalled in its original position.
  1. Remove the valves.
    1. Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove the lock retainer (A).
      When installing the SST, insert the front support (A) directly into the bolt hole on the cylinder head.
      Do not depress the valve retainer more than 12 mm (0.47 in.).
    2. Remove the spring seat (B).
    3. Remove the valve spring (C).
    4. Remove the valve (D).
    5. Using needle-nose pliers, remove the valve stem seal (E).
      Do not reuse the valve stem oil seals.

Inspection

Cylinder head cover
  1. Inspect for flatness.
    Using a precision straightedge and feeler gauge, measure the cylinder block and manifold contact surfaces for warpage. Cylinder head gasket surface flatness: Overall less than 0.05 mm (0.0020 in.). Less than 0.02 mm (0.0008 in.) per 100 mm (3.9370 in.) x 100 mm (3.9370 in.) area.

    Manifold mounting surface flatness: Less than 0.10 mm (0.0039 in.)

  2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and the cylinder head 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 Intake: 5.500 - 5.512 mm (0.21654 - 0.21701 in.) Exhaust: 5.500 - 5.512 mm (0.21654 - 0.21701 in.)
    2. Using a micrometer, measure the diameter of the valve stem. Valve stem outside diameter Intake: 5.465 - 5.480 mm (0.21516 - 0.21575 in.) Exhaust: 5.458 - 5.470 mm (0.21488 - 0.21535 in.)
    3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement. If the clearance is greater than specified, replace the valve or the cylinder head. Valve stem-to-guide clearance [Standard] Intake: 0.020 - 0.047 mm (0.00079 - 0.00185 in.) Exhaust: 0.030 - 0.054 mm (0.00118 - 0.00213 in.)
  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 is less than specified, replace the valve.

      Margin thickness [Standard] Intake: 1.30 mm (0.0512 in.) Exhaust: 1.26 mm (0.0496 in.)

    4. Check the valve length. Valve length [Standard] Intake: 102.22 mm (4.0244 in.) Exhaust: 104.04 mm (4.0961 in.) [Limit] Intake: 101.97 mm (4.0146 in.) Exhaust: 103.79 mm (4.0862 in.)
    5. Check the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
  5. Inspect the valve seats and valve guides.
    1. 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.
    2. Check 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 vernier caliper, measure the valve spring free length. If the free length is not within specification, replace the valve spring. Valve Spring [Standard] Free Height: 45.93 mm (1.8083 in.) Out-of-Square: Less than 1.5°
  7. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. If the lobe height is less than specified, replace the camshaft.

    Cam Lobe Height Intake: 39.0 mm (1.5354 in) Exhaust: 39.0 mm (1.5354 in)

  8. Inspect the camshaft journal surfaces for wear. If a journal is excessively worn, replace the camshaft.
  9. Inspect the camshaft journal oil clearance.
    1. Clean the camshaft bearing caps and journals.
    2. Install the camshafts on the cylinder head.
    3. Place a strip of Plastigage on each camshaft journal.
    4. Install the bearing caps and tighten the bolts to the specified torque. Tightening torque: M6 bolts: 11.8 ~ 13.7 N·m M8 bolts: 18.6 ~ 23 N·m
      Do not rotate the camshaft.
    5. Remove the bearing caps.
    6. Measure the Plastigage at its widest point. If the oil clearance is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.

      Camshaft Bearing Oil Clearance Standard: 0.032 ~ 0.062 mm (0.00126 ~ 0.00244 in)

  10. Inspect the camshaft end play.
    1. Install the camshaft bearing caps.
    2. Using a dial indicator, measure the camshaft end play by moving the camshaft forward and backward. If the end play exceeds the specification, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Camshaft end play Standard: 0.10 – 0.19 mm (0.0039 – 0.0075 in.)
    3. Remove the camshafts.
  11. Inspect the CVVT for smooth rotation.
    1. Clamp the camshaft in a vise. Be careful not to damage the cam lobes and journals in the vise.
    2. Make sure the CVVT is locked by turning it clockwise or counterclockwise. It should not rotate.
    3. Intake CVVT: Tape over one of the two advance holes in the camshaft journal. Exhaust CVVT: Tape over one of the two retard holes in the camshaft journal.
    4. Intake CVVT: Apply approx. 150 kPa (1.5 kgf/cm², 21 psi) of compressed air to the unsealed supply hole to release the lock. Exhaust CVVT: Apply approx. 150 kPa (1.5 kgf/cm², 21 psi) of compressed air to the unsealed retard hole to release the lock.
      When applying compressed air, cover the oil passages with a cloth to prevent oil from splashing.
    5. Intake CVVT: While applying compressed air, rotate the CVVT in the advance direction (counterclockwise) within its phase range, and check that the CVVT rotates smoothly. Exhaust CVVT: While applying compressed air, rotate the CVVT in the retard direction (clockwise), and check that the CVVT rotates smoothly. CVVT Phase Range Intake: 25°±1° (from most retarded position to most advanced position) Exhaust: 20°±1° (from most advanced position to most retarded position)
    6. Intake CVVT: Rotate the CVVT to the most retarded position (clockwise), then make sure the CVVT is locked. Exhaust CVVT: Rotate the CVVT to the most advanced position (counterclockwise), then make sure the CVVT is locked.
Valve and Valve Spring Camshaft Continuously Variable Valve Timing (CVVT) Assembly HLA (Hydraulic Lash Adjuster) With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
Symptom Possible Cause Action
1. Temporary noise when starting a cold engine Normal This noise will disappear after the engine oil reaches normal pressure.
2. Continuous noise when starting the engine after it has been parked for more than 48 hours. Oil leakage from the HLA high-pressure chamber allowing air to enter The noise will disappear within 15 minutes with the engine running at 2000-3000 rpm.
If it does not disappear, see step 7 below.
3. Continuous noise when starting the engine for the first time after cylinder head overhaul. Insufficient oil in the cylinder head oil passage
4. Continuous noise when starting the engine after excessive cranking with the starter.
  • Oil leakage from the HLA high-pressure chamber allowing air to enter
  • Insufficient oil in the HLA
5. Continuous noise while the engine is running after HLA replacement
Do not run the engine above 3000 rpm, as this may damage the HLA.
6. Continuous noise at idle after high engine speed operation. Engine oil level is too high or too low
  • Check the oil level.
  • Drain or add oil as necessary.
Excessive air in the oil at high engine speed Check the oil supply system.
Deteriorated oil Check the oil quality.
If deteriorated, replace with the specified type.
7. Noise continues for more than 15 minutes Low oil pressure Check the oil pressure and the oil supply system to each engine component.
Faulty HLA Remove the cylinder head cover and press the HLA by hand.
If it moves, replace the HLA.

Installation
  • Thoroughly clean all parts to be assembled.
  • Before installing parts, apply new engine oil to all sliding and rotating surfaces.
  • Replace the oil seals with new ones.
  1. Install the valves.
    1. Using SST (09222-2E000), install a new stem seal (A).
      • Do not reuse the old valve stem oil seals.
      • Improper seal installation may cause oil to leak past the valve guides.
    2. Install the valve, valve spring and spring seat.
      Position the valve springs so that the side coated with paint faces the retainer, then install the retainer.
    3. Using SST (09222-3K000, 09222-3K100), compress the spring and install the lock retainers. Before releasing the valve spring compression, make sure the lock retainers are correctly seated by pressing and releasing the compressor handle 2 to 3 times.
      When installing the SST, insert the front support (A) directly into the bolt hole on the cylinder head.
      Do not depress the valve retainer more than 12 mm (0.47 in.).

Installation
  • Thoroughly clean all parts to be assembled.
  • Always use new cylinder head gaskets and manifold gaskets.
  • Always use new cylinder head bolts.
  • The cylinder head gasket is a metal gasket. Be careful not to bend it.
  • Turn the crankshaft to position the No. 1 piston at top dead center (TDC) on the compression stroke.
  1. Install the cylinder head gasket (B) on the cylinder block.
    1. Remove hardened sealant, oil, dust, moisture and harmful foreign material from the cylinder block and cylinder head.
    2. Apply liquid gasket to the edge of the cylinder block.
    3. Install the cylinder head gasket using the cylinder block dowel pins.
    4. Apply liquid gasket to the edge of the cylinder head gasket.
      Apply liquid gasket to the edge of the cylinder block and the cylinder head gasket.

      Sealant: Threebond 1217H or equivalent
      Assemble the cylinder head gasket and cylinder head within 5 minutes after applying sealant.
  2. Carefully place the cylinder head (A) so as not to damage the cylinder head gasket during installation.
  3. Install the cylinder head bolts with washers. Using the SST (09221-4A000), install and tighten the 10 cylinder head bolts in several passes in the specified sequence. Tightening torque: Step 1: 32.4 to 36 N·m Step 2: 90 to 95° Step 3: 90 to 95°
    • Do not reuse the cylinder head bolts.
    • Do not apply engine oil to the bolt threads to achieve the correct tightening torque.
    • Remove any sealant that squeezes out within 5 minutes after installing the cylinder head bolts.
    • Do not start the engine or perform a pressure test within 30 minutes after installing the cylinder head bolts.
    • Be careful not to change the installed position of the pre-assembled washer bolts and the unassembled washer bolts.
    • When installing the washers from the unassembled washer bolts, the rounded edge and chamfer of the washers must face up.
  4. Install the spark plugs (A). (Refer to Engine Electrical System - "Ignition System")

    Tightening Torque: 14.7 – 24 N·m

  5. Install the rear engine mount (A).

    Tightening torque: 34.3 to 39 N·m

  6. Install the exhaust OCV (Oil Control Valve) (A).

    Tightening torque: 9.8 ~ 11.8 N·m

  7. Install the intake OCV (Oil Control Valve) (A).

    Tightening torque: 9.8 ~ 11.8 N·m
    • Do not reuse an OCV that has been dropped.
    • Keep the OCV filter clean.
    • Do not hold the OCV sleeve (A) during service.
    • When the OCV is installed on the engine, do not move the engine by holding the OCV connector.
  8. Install the oil control adapter (A) with a new gasket (B).

    Tightening torque: 9.8 ~ 11.8 N·m

  9. Install the water temperature control unit. (Refer to Cooling System in this group)
  10. Tighten the heater pipe mounting bolts (B).

    Torque: 19.6 ~ 24 N·m
    Do not reuse the sealing bolts.
  11. Connect the bypass hose (A).
  12. Install the HLA (Hydraulic Lash Adjuster) (A) and rocker arm (B).
    1. When installing the HLA, hold it upright so that engine oil in the HLA does not spill and dust does not adhere to the HLA.
    2. Insert the HLA carefully into the cylinder head to avoid spilling engine oil.
      If oil is spilled, bleed the air according to the air bleeding procedure. Press the HLA 4 to 5 times in diesel fuel while lightly pressing on its cap with a hard steel wire tip. (Be careful not to press the steel wire too hard, as the ball weighs several grams.)
  13. Install the camshaft carrier.
    1. Using a gasket scraper, remove all old sealant from the gasket surfaces.
    2. There must be no harmful foreign material, oil, dust, or moisture at the sealant application locations on the camshaft holder and the cylinder head. Spray cleaner on the surface and wipe with a clean cloth.
    3. After applying liquid sealant to the bottom surface of the camshaft holder, install the camshaft holder. A continuous bead of sealant must be applied to prevent any oil leakage path. Bead width: 2.5 to 3.5 mm (0.10 to 0.14 in.) Sealant: Threebond 1217H or equivalent
    4. Place the camshaft holder (A) on the cylinder head. Use the dowel pins on the camshaft holder and the holes in the cylinder head as guides to install the camshaft holder in the correct position.
    5. Tighten the camshaft carrier bolts.

      Tightening Torque: 18.6 ~ 23 N·m
      • Install the camshaft holder within 5 minutes after applying sealant.
      • Install the camshaft bearing cap within 5 minutes after installing the camshaft holder.
      • Do not start the engine or perform a pressure test within 30 minutes after installing the camshaft holder.
  14. Install the camshafts.
    1. Place the intake and exhaust camshafts (A) on the camshaft holder.
    2. Install the camshaft bearing cap (A).
      Tighten the bolts in several passes in the specified sequence. Tightening torque — M6 bolts: 11.8 – 13.7 N·m; M8 bolts: 18.6 – 23 N·m
      Be careful not to change the position or direction of the bearing caps.
  15. Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).

    Tightening torque: 64.7 ~ 76 N·m
    When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent it from rotating.
  16. Install the fuel pump adapter assembly (A).

    Tightening torque: 21.6 ~ 26 N·m

  17. Install the condenser (A).

    Tightening torque: 9.8 ~ 11.8 N·m

  18. Install the high-pressure pipe (A) and PCSV (Purge Control Solenoid Valve) bracket (B). (Refer to Engine Control System/Fuel System - "High Pressure Fuel Pump") Tightening Torque High-Pressure Pipe Nut: 26.5 to 32 N·m Bracket Bolt: 9.8 to 11.8 N·m
  19. Install the vacuum hose (A).

    Tightening torque: 9.8 ~ 11.8 N·m

  20. Install the injector and fuel rail assembly (A). (Refer to Engine Control/Fuel System - "Injector")

    Tightening Torque: 18.6 ~ 24 N·m

  21. Install the foam injector (A).
  22. Install the timing chain, including the drive belt, cylinder head cover, generator and timing chain cover. (Refer to Timing System in this group)
  23. Install the intake manifold and exhaust manifold. (Refer to Intake and Exhaust Systems in this group)
  24. Connect the fuel hose (A) and the PCSV (Purge Control Solenoid Valve) hose (B).
  25. Connect the heater hoses (A).
    When installing the heater hoses, install them as shown in the illustrations.
  26. Install the wiring harness and protectors on the cylinder head and intake manifold, then connect the wiring harness connectors and clamps.
    1. OCV (Oil Control Valve) Intake Connector (A)
    2. OCV (Oil Control Valve) Exhaust Connector (A)
    3. Alternator Connector (A)
    4. Ignition coil connectors (A)
    5. Fuel pump connector (B)
    6. CMPS (Camshaft Position Sensor) Intake Connector (A)
    7. CMPS (Camshaft Position Sensor) Exhaust Connector (B)
    8. Injector Extension Connector (A)
    9. Front HO2S (Heated Oxygen Sensor) Connector (A)
    10. Condenser Connector (A)
    11. PCSV (Purge Control Solenoid Valve) Connector (A)
    12. ECTS (Engine Coolant Temperature Sensor) Connector (A)
    13. VIS (Variable Intake System) Connector (A)
    14. MAPS (Manifold Absolute Pressure Sensor) and IATS (Intake Air Temperature Sensor) Connector (A)
    15. ETC (Electronic Throttle Control) Connector (A)
  27. Connect the upper radiator hose and lower hose. (Refer to Cooling System in this group)
  28. Install the air duct and air cleaner assembly. (Refer to Intake and Exhaust Systems in this group)
  29. Install the engine cover. (Refer to Engine and Transaxle Assembly in this group)
  30. Install the under cover. (Refer to Engine and Transaxle Assembly in this group)
  31. Install the right front wheel. (Refer to Suspension System - "Wheel")
  32. Connect the negative battery terminal. (Refer to Engine and Transaxle Assembly in this group)
  33. Add all required fluids and check for leaks. Connect the GDS. Check for DTCs, note them, and clear them. Recheck.
  • Fill the engine with engine oil.
  • Fill the radiator and the coolant reservoir with engine coolant.
  • Clean the battery terminal posts and cable clamps, then assemble.
  • Inspect for fuel leaks.
  • After assembling the fuel line, turn the ignition ON (do not crank the engine) so the fuel pump operates for approximately two seconds to pressurize the fuel line.
  • Repeat this procedure two or three times, then check all fuel line connections for leaks.
  • Bleed air from the cooling system.
  • Start the engine and let it run until warm (until the radiator fan cycles 3 or 4 times).
  • Turn the engine off. Check the coolant level in the radiator and add coolant if necessary. This allows trapped air to be removed from the cooling system.
  • Tightly close the radiator cap, then restart the engine and check for leaks.

Test yourself

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