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Hyundai Equus Manuals

Hyundai Equus: Cylinder Head Repair procedures - Cylinder Head Assembly - Engine Mechanical System - Hyundai Equus VI 2009-2024 Service ManualHyundai Equus: Cylinder Head Repair procedures

Second generation VI (2009–2024) / Hyundai Equus VI 2009-2024 Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Repair procedures

Removal
   
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal operating temperature before removing it.
•
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
   
•
Mark all wiring and hoses to avoid misconnection.
•
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1.
Disconnect the negative terminal (A) from the battery.

2.
Remove the engine room cover (A), engine cover (B) and radiator grill upper cover (C).

3.
Loosen the drain plug (A) and drain the engine coolant. Remove the radiator cap to speed draining.
   
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

4.
Remove the air cleaner assembly.
(1)
Remove the air duct (A).
(2)
Disconnect the breather hose (B).
(3)
Loosen the clamp (C) and then disconnect the air intake hose from the throttle body.
Tightening torque :
2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
(4)
Remove the chamber air cleaner (D) and air cleaner assembly (E).
Tightening torque
Air cleaner assembly bolts:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

5.
Disconnect the radiator upper hose (A) and lower hose (B).

6.
Remove the fuel hose (A), the purge control solenoid valve (PCSV) hose (B) and the brake booster vacuum hose (C).

7.
Disconnect the heater hoses (A).

8.
Remove the radiator & cooling fan assembly from the vehicle.
(Refer to Cooling system in this group)
9.
Turn the tensioner (B) clockwise and loosen, then remove the drive belt (A).

10.
Disconnect the engine wiring harness connectors and hoses.
(1)
ETC module connector (A)
(2)
PCSV connector (B)
(3)
PCV hose (C)

(4)
Engine coolant temperature sensor (ECTS) connector (A)
(5)
RH intake oil control valve (OCV) connector (B)
(6)
RH exhaust oil control valve (OCV) connector (C)

(7)
Alternator connector (A)

(8)
RH ignition coil connectors (A)
(9)
RH fuel pump connector (B)
(10)
RH exhaust camshaft position sensor (CMPS) connector (C)
(11)
RH intake camshaft position sensor (CMPS) connector (D)

(12)
RH knock sensor connectors (A,B)
(13)
RH front oxygen sensor (HO2S) connector (C)
(14)
RH ignition coil condenser connector (D)
(15)
Ground (E)

(16)
Oil pressure switch (OPS) connector (A)
(17)
LH intake oil control valve (OCV) connector (B)
(18)
LH exhaust oil control valve (OCV) connector (C)
(19)
Compressor connector (D)

(20)
LH ignition coil connectors (A)
(21)
LH fuel pump connector (B)
(22)
LH intake camshaft position sensor (CMPS) connector (C)
(23)
LH exhaust camshaft position sensor (CMPS) connector (D)

(24)
LH knock sensor connectors (A,B)
(25)
Manifold absolute pressure (MAP) sensor connector (C)
(26)
Crankshaft position sensor (CKPS) connector (D)
(27)
LH ignition coil condenser connector (E)
(28)
LH front oxygen sensor (HO2S) connector (F)
(29)
Ground (G)
(30)
Injector connectors (H)

11.
Remove the oil level gauge (A).

12.
Remove the high pressure fuel pipe bracket bolt (A), low pressure fuel tube bracket bolts (B) and the injector connector bracket bolt (C).

13.
Remove the intake manifold module (A).

14.
Remove the low pressure fuel tube (A).
(Refer to FL group)

15.
Remove the LH/RH high pressure fuel pipes (A).
(Refer to FL group)

16.
Disconnect the cross over pipe (A) and then remove the LH/RH injector & rail assembly (B).
(Refer to FL group)

17.
Remove the LH/RH knock sensors (A) and then remove the wiring assembly bracket (B).

18.
Remove the water hose (A).

19.
Remove the LH/RH ignition coils (A).

20.
Remove the LH/RH fuel pumps (A).
(Refer to FL group)

21.
Remove the LH/RH cylinder head covers (A).

22.
Remove the cylinder head cover gasket (A), oil seal (B) and the fuel pump adapter gasket (C).

23.
Remove the oil pressure switch (OPS) wiring assembly and bracket (A).

24.
Remove the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).

25.
Remove the LH/RH exhaust manifold heat protectors (A).

26.
Remove the LH/RH exhaust manifolds (A).
(Refer to intake and exhaust system in this group)

27.
Remove the LH/RH intake/exhaust oil control valve (OCV) & filter assemblies (A).

   
•
Do not reuse the OCV when dropped.
•
Keep the OCV clean.
•
Do not hold the OCV sleeve (A) during servicing.
•
When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

28.
Remove the LH/RH timing chain upper covers (A).

29.
Remove the LH/RH timing chain upper cover gaskets (A).

30.
Remove the LH/RH cam to cam guides (A).

31.
Align the LH/RH timing mark of CVVT sprocket.
[RH]

[LH]

   
In case that the timing system has been completely disassembled, the timing chain can be installed with all of chain installation mark of the sprocket and timing marked chain links aligned without additional marking. However, during on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), when it is not necessary to remove the timing chain completely, mark the timing chain links corresponding to the chain installation marks on the sprocket with an ndication mark with a suitable marking paint pen when the No.1 piston is at TDC position because it is very difficult to align all of the chain installation mark of the sprocket and the timing marked chain links.
32.
Remove the water outlet pipe (A) and the water inlet pipe (B).

   
Remove the drain plug (A) and drain the engine coolant.

33.
Remove the water temperature control assembly (A) and the water outlet fitting assembly (B).

34.
Remove the LH/RH timing chain tensioners (A) and chain guide fixing bolts (B).

35.
Remove the LH/RH fuel pump adapters (A) and the roller tappets (B).

36.
Remove the LH/RH camshaft bearing caps (A) and the camshaft thrust bearing caps (B).

   
If removing CVVT assembly only, hold the hexagonal position of camshaft by wrench not to rotate during loosen the CVVT bolts as below.
Tightening torque :
73.5 ~ 83.4 N.m (7.5 ~ 8.5 kgf.m, 54.2 ~ 61.5 lb-ft)

   
When installing the CVVT assembly.Align the CVVT groove with camshaft drill point.
37.
Seperate the timing chain from the sprocket and then, remove the LH/RH camshafts and CVVT assemblies (A).

   
Lift up the rear of camshaft slightly (1) and then remove it from back to engine frontward (2).
Take care not to damage camshaft journal, cam lobe and the camshaft carrier journal.
38.
Remove the LH/RH camshaft carriers (A).

39.
Remove the roller finger follower and the hydraulic lash adjuster (HLA) assembly (A).

40.
Remove the LH/RH cylinder heads (A).
(1)
Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

   
Head warpage or cracking could result from removing bolts in an incorrect order.
[RH]

[LH]

(2)
Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.
   
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
41.
Remove the LH/RH cylinder head gaskets (A).

Disassembly
1.
Remove the valves.
(1)
Using the SST (09222-3K000, 09222-3C310), compress the valve spring and remove retainer lock.

(2)
Remove the spring retainer.
(3)
Remove the valve spring.
(4)
Remove the valve.
(5)
Remove the valve stem seal.
   
Do not reuse old valve stem seals.
Inspection
Cylinder Head
1.
Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in)
[Less than 0.02mm(0.0008in)/100x100]
Flatness of manifold gasket surface
Standard : Less than 0.1mm(0.004in)
[Less than 0.03mm(0.0012in)/110x110]

2.
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Valve And Valve Spring
1.
Inspect valve stems and valve guides.
(1)
Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust :
6.000 ~ 6.012mm (0.2362 ~ 0.2367in)

(2)
Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.965 ~ 5.980mm (0.2348 ~ 0.2354in)
Exhaust : 5.958 ~ 5.970mm (0.2346 ~ 0.2350in)

(3)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
2.
Inspect valves.
(1)
Check the valve is ground to the correct valve face angle.
Valve face angle :
Intake/Exhaust : 45.25°~ 45.75°
(2)
Check that the surface of the valve 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 minimum, replace the valve.
Margin
Intake : 1.2mm (0.0472in)
Exhaust : 1.2mm (0.0472in)

(4)
Check the valve length.
Length
Intake : 107.77mm (4.2429in)
Exhaust : 107.75mm (4.2421in)
(5)
Check the surface of the valve stem tip for wear.If the valve stem tip is worn, replace the valve.
3.
Inspect valve seats.
(1)
Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace cylinder head.
(2)
Check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Valve seat contact width :
Intake : 1.15 ~ 1.45mm (0.0453 ~ 0.0571in)
Exhaust : 1.35 ~ 1.65mm (0.0531 ~ 0.0650in)
Valve seat angle :
Intake/Exhaust : 44.75° ~ 45.10°
4.
Inspect valve springs.
(1)
Using a steel square, measure the out-of-square of the valve spring.
(2)
Using vernier calipers, measure the free length of the valve spring.
Valve spring
Free height : 48.44mm (1.9070in)
Out-of-square : 1.5°

Camshaft
1.
Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 41.77mm (1.6444in)
Exhaust : 41.5mm (1.6338in)

If the cam lobe height is less than standard, replace the camshaft.
2.
Inspect the camshaft journal clearance.
(1)
Clean the bearing caps and camshaft journals.
(2)
Place the camshafts on the cylinder head.
(3)
Lay a strip of plastigage across each of the camshaft journals.

(4)
Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque
10mm bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
12mm bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
   
Do not turn the camshaft.
[RH]

[LH]

(5)
Remove the bearing caps.
(6)
Measure the plastigage at its widest point.
Camshaft bearing oil clearance
Intake/Exhaust :
No.1 journal :
0.025 ~ 0.057mm (0.0010 ~ 0.0022in)
No.2, 3, 4, 5 journal :
0.020 ~ 0.057mm (0.0008 ~ 0.0022in)
Camshaft journal outer diameter
Intake/Exhaust :
No.1 journal :
35.964 ~ 35.980mm (1.4159 ~ 1.4165in)
No.2, 3, 4, 5 journal :
25.964 ~ 25.980mm (1.0222 ~ 1.0228in)
Camshaft journal bore inner diameter
Intake/Exhaust :
No.1 journal :
36.005 ~ 36.021mm (1.4175 ~ 1.4181in)
No.2, 3, 4, 5 journal :
26.000 ~ 26.021mm (1.0236 ~ 1.0244in)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7)
Completely remove the plastigage.
(8)
Remove the camshafts.
3.
Inspect the camshaft end play.
(1)
Install the camshafts.
(2)
Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque
10mm bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
12mm bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
   
Do not turn the camshaft.
[RH]

[LH]

(3)
Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play :
0.12 ~ 0.22mm (0.0047 ~ 0.0086in)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(4)
Remove the camshafts.
CVVT Assembly
1.
Inspect the CVVT assembly.
(1)
Check that the CVVT assembly will not turn.
(2)
Ex-CVVT: Apply vinyl tape to one of the retard holes.
In-CVVT: Apply vinyl tape to one of the advance holes.

(3)
Wrap tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cmx, 21psi) to the port of the camshaft. (Perform this in order to release the lock pin for the maximum default angle locking.)
In-default : Max retard
Ex-default : Max advance
   
When the oil splashes, wipe it off with a shop rag.
(4)
Under the condition of (3), turn the In-CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the In-CVVT assembly will turn to the advance side without applying force by hand.
Under the condition of (3), turn the Ex-CVVT assembly to the retard angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the Ex-CVVT assembly will turn to the retard side without applying force by hand.

(5)
Except the position where the lock pin meets at the maximum default angle, let the CVVT assembly turn back and forth and check the movable range and that there is no interference.
Standard :
Movable smoothly in the range about 22.5°±1°
(6)
Turn the In-CVVT assembly clockwise with your hand and lock it at the maximum retard angle position.
Turn the Ex-CVVT assembly counter clockwise with your hand and lock it at the maximum advance angle position.
HLA (Hydraulic Lash Adjuster)
With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.

Problem
Possible cause
Action
1. Temporary noise when starting a cold engine
Normal
This noise will disappear after the oil in the engine reaches the normal pressure.
2. Continuous noise when the engine is started after parking more than 48 hours.
Oil leakage of the high pressure chamber on the HLA, allowing air to get in.
Noise will disappear within 15 minutes when engine runs at 2000-3000 rpm.If it doesn’t disappear, refer to step 7 below.
3. Continuous noise when the engine is first started after rebuilding cylinder head.
Insufficient oil in cylinder head oil gallery.
4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band.
Oil leakage of the high-pressure chamber in the HLA, allowing air to get in.Insufficient oil in the HLA.
5. Continuous noise when the engine is running after changing the HLA.
   
Do not run engine at a speed higher than 3000 rpm, as this may damage the HLA.
6. Continuous noise during idle after high engine speed.
Engine oil level too high or too low.
Check oil level.Drain or add oil as necessary.
Excessive amount of air in the oil at high engine speed.
Check oil supply system.
Deteriorated oil.
Check oil quality.If deteriorated, replace with specified type.
7. Noise continues for more than 15 minutes.
Low oil pressure.
Check oil pressure and oil supply system of each part of engine.
Faulty HLA.
Remove the cylinder head cover and press HLA down by hand.If it moves, replace the HLA.
   
Be careful as the HLA may be hot.

Air Vent Procedure
[In case of HLA alone]
1.
Stroke HLA in gas oil 4~5 times by pushing 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(g).

[After installed on vehicle]
   
After installed on engine, HLA might give out unusual noise if air is mingled. Then apply slow racing as below.
1.
Racing at idle rpm for 1~3 minutes.
2.
Repeat the racing with below pattern.

3.
Check the abnormal noise during racing. (Usually, abnormal noise would be removed after 10~30 times racing above pattern. If there is abnormal noise after 30 times racing, find another reason except aeration in HLA)
4.
Racing 5 times more after removing the abnormal noise.
5.
Stop the air vent procedure after checking removing of abnormal noise for 1~3 minutes at idle rpm.
Reassembly
   
•
Thoroughly clean all parts to be assembled.
•
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
•
Replace oil seals with new ones.
1.
Install the valves.
(1)
Using the SST (09222-28200), push in the new valve stem seals.
   
•
Do not reuse old valve stem seals.
•
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2)
Install the valve, valve spring and spring retainer.
   
Place valve springs so that the smaller outer diameter side faces toward the valve spring retainer and then install the retainer.
(3)
Using the SST (09222 - 3K000, 09222-3C310), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place 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 retainer lock..
Installation
   
•
Thoroughly clean all parts to be assembled.
•
Always use a new head and manifold gasket.
•
The cylinder head gasket is a metal gasket. Take care not to bend it.
•
Rotate the crankshaft, set the No.1 piston at TDC.
1.
Install the cylinder head gasket (A).
(1)
The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oil and etc.
(2)
Before assembling the cylinder head gasket, the liquid sealant LT5900H or equivalent should be applied on the gap between cylinder block and timing chain lower case.
The part must be assembled within 5 minutes after sealant was applied.
   
Refer to below illustration to apply the sealant.
Bead width :
3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in)
Sealant locations :
1.5 ~ 2.5mm (0.0591 ~ 0.0984 in)
from timing chain lower case inner surface
Recommended sealant : Liquid sealant LT5900H (Hyundai : Gray RTV) or equivalent

(3)
Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
   
Be careful of the installation direction.
(4)
Install the LH/RH cylinder heads (A).
   
Wipe away any excess liquid sealant that may appear after assembling cylinder heads.

2.
Install the cylinder head bolts.
(1)
Do not apply engine oil on the cylinder head bolts.
(2)
Using SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque
Cylinder head bolts (1~10) :
32.4 ~ 36.3 N.m(3.3 ~ 3.7 kgf.m, 23.9 ~ 26.8 lb-ft) +
88° ~ 92°+ 118° ~ 122°
Flange bolts (11~12) :
33.3 ~ 36.3 N.m(3.4 ~ 3.7 kgf.m, 24.6 ~ 26.8 lb-ft)
   
Always use new cylinder head bolts.
[RH]

[LH]

3.
Install the LH/RH camshaft carrier assemblies.
(1)
Apply liquid sealant on the bottom surface of the carrier.
Bead width :
2.5 ~3.5mm (0.0984 ~ 0.1377in.)
Sealant location :
1.0 ~ 2.0mm (0.0393 ~ 0.0787in.)
from carrier bottom face chamber edge
Recommended sealant :
Liquid sealant LT 5900 (Hyundai : Gray RTV) or equivalent
[LH]

[RH]

   
-
The part must be assembled within 5 minutes after sealant was applied.
-
To apply the sealant continuously on hatched area of carrier bottom face.
-
If when sealant is applied to cylinder head top face, sealant position to be same with position that is applied to carrier rail position.
-
To remove oil, dust, etc. on the top face of cylinder head and the bottom face of carrier.
(2)
Install the LH/RH camshaft carriers (A).
Tightening torque
Carrier bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
*LH engine hanger & carrier bolts (2EA) :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

   
To assemble the camshaft bearing caps within 5 minutes after assembling camshaft carrier.
4.
Assemble the CVVT and camshaft assembly.
Tightening torque :
73.5 ~ 83.4 N.m(7.5 ~ 8.5 kgf.m, 54.2 ~ 61.5 lb-ft)

A.
Align the CVVT groove with camshaft drill point.
B.
Assemble the camshaft to the dowel pin of CVVT assembly. At this time, attend not to be assembled to oil hole of camshaft.
C.
Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt to the CVVT assembly.
D.
Do not rotate the CVVT assembly when the camshaft is assembled to the dowel pin of CVVT assembly.
5.
Install the roller finger follower and the hydraulic lash adjuster assembly (A).

(1)
Until installing HLA shall be held upright so that engine oil in HLA should not spill and assured that dust does not adhere to HLA.
(2)
HLA shall be inserted tenderly to the cylinder head not to spill engine oil from HLA. In case of spilling, air vent shall be done in accordance with the air vent procedure. (Refer to HLA inspection)
6.
Install the LH/RH CVVT and camshaft assemblies (A).

   
Install the camshaft & CVVT assemblies from front to engine backward (1) and then put the camshaft rear down slightly (2).
Take care not to damage camshaft journal, cam lobe and the camshaft carrier journal.
   
•
Apply a light coat of engine oil on camshaft journals.
•
Assemble the timing mark of CVVT to the same level of cylinder head top surface.
•
Make sure the right, left bank, intake, exhaust side camshaft are correct before assembling.
•
Turn the crankshaft to set the No.1 piston at TDC position.
Camshaft identification mark

Type
A
B
C
LH
Intake
-
-
-
Exhaust
Black
-
-
RH
Intake
-
Black
-
Exhaust
-
-
Black

7.
Install the timing chain to the CVVT sprocket.

   
•
Make sure the crankshaft is at TDC position.
•
Align the chain installation mark of the crankshaft sprocket and the timing mark of the chain link, and then install the chain.
   
In case of marking the timing chain links corresponding to the chain installation marks on the sprocket with an identification for on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), align all of the chain installation mark of the sprocket and the timing marked chain links for reassembly.
   
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket > Timing chain guide > Exhaust CVVT sprocket > Intake CVVT sprocket. (LH Bank)
Crankshaft sprocket > Timing chain guide > Intake CVVT sprocket > Exhaust CVVT sprocket. (RH Bank)
When reassembling the timing chain, make sure all of the chain installation mark of the sprocket and the timing marked chain links (orange color) are aligned.
8.
Install the LH/RH camshaft bearing caps (A) and the camshaft thrust bearing caps (B).
Tighten the bolts in order to below sequence.
Tightening torque
10mm bolts :
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
12mm bolts :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
[RH]

[LH]

   
Be sure to install the thrust bearing cap and bearing cap bolts in the correct position and facing direction.
9.
Install the LH/RH fuel pump adapters (A) and the roller tappets (B). (Refer to FL group)
Tightening torque :
18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

10.
Install the LH/RH cam to cam guides (A).
Tightening torque :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

11.
Confirm that the LH/RH timing chain tensioner is transport position by pressed as below.
The hook must be around the pin.
[LH]

[RH]

12.
Install the LH timing chain guide bolt (B) and then the LH timing chain tensioner (A).
(1)
Install the timing chain tensioner in the hole on the cylinder head by hand.
(2)
Tighten the tensioner mounting bolts.
Tightening torque :
Timing chain guide bolt :
21.6 ~ 25.5 Nm (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)
Timing chain tensioner bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
   
-
Confirm identification mark 'L' on the tensioner flange.
-
The tensioner ratchet should be topward.

13.
Install the RH timing chain guide bolt (B) and then the RH timing chain tensioner (A).
(1)
Install the timing chain tensioner in the hole on the cylinder head by hand.
(2)
Tighten the tensioner mounting bolts.
Tightening torque :
Timing chain guide bolt :
21.6 ~ 25.5 Nm (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)
Timing chain tensioner bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
   
-
Confirm identification mark 'R' on the tensioner flange and the gasket hole.
-
The tensioner ratchet should be topward.

14.
Set tension of the LH/RH timing chain tensioner.
(1)
LH Bank
A.
To set tension of the timing chain tensioner, push the timing chain tensioner arm outward to the end.
(Tensioner plunger moves back about 2~3mm (0.0787 ~ 0.1181in.))
B.
Tension of the timing chain tensioner will set after the lock is released.
If the tensioner tooth is visible, tension setting is completed.

(2)
RH Bank
A.
To set tension of the timing chain tensioner, push the timing chain tensioner arm outward to the end.
(Tensioner plunger moves back about 2~3mm (0.0787 ~ 0.1181in.))
B.
Tension of the timing chain tensioner will set after the lock is released.
If the tensioner tooth is visible, tension setting is completed.

(3)
After setting tension of the LH, RH timing chain tensioner, check timing mark again.
A.
Make sure the chain installation mark of the sprocket and the timing marked chain links are aligned.
B.
Rotate the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing marks on the LH, RH intake and exhaust CVVT and the RH cylinder head upper surfaces are aligned.
15.
After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
   
Always turn the crankshaft clockwise.
Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.
16.
Install the water temperature control assembly (A) and the water outlet fitting assembly (B) with new O-ring and new gasket.
Tightening torque
Water temperature control assembly bolts :
16.7 ~ 19.6 N.m (1.7 ~ 2.0 kgf.m, 12.3 ~ 14.5 lb-ft)
Water outlet fitting bolts (M8) :
16.7 ~ 19.6 N.m (1.7 ~ 2.0 kgf.m, 12.3 ~ 14.5 lb-ft)
Water outlet fitting bolt (M6) :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

17.
Install the water outlet pipe (A) and the water inlet pipe (B).
Tightening torque :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
   
•
Use new O-rings when reassembling.
•
Never apply sort of oil on O-ring and O-ring groove of pipe end.
•
O-ring must be free from scratching damage.
•
Make clean the contact face before assembly.
•
Insert pipe after to be wetting O-ring or inside of attaching hole by water or antifreeze.

   
Install the drain plug (A).
Tightening torque :
96.1 ~ 100.0 N.m (9.8 ~ 10.2 kgf.m, 70.9 ~ 73.8 lb-ft)

18.
Install the LH/RH timing chain upper covers.
(1)
Install the new timing chain upper cover gaskets (A).

(2)
Before assembling the timing chain upper cover, the liquid sealant LT5900H (Hyundai : Gray RTV) or equivalent should be applied on upper cover.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : O2.5 ± 0.5mm (0.1 ± 0.002in)
Area (A) (4EA) : O4.0 ± 0.5mm (0.16 ± 0.002in)

   
•
Clean the sealing face before assembling two parts.
•
Remove harmful foreign materials on the sealing face before applying sealant.
•
When applying sealant gasket, sealant must not protrude into the inside of upper cover.
•
To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(3)
Install the LH/RH timing chain upper covers (A).
Tightening torque :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

19.
Install the LH/RH intake/exhaust oil control valves (OCV) (A).
Tightening torque :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   
•
Do not reuse the OCV when dropped.
•
Keep the OCV clean.
•
Do not hold the OCV sleeve (A) during servicing.
•
When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

20.
Install the LH/RH exhaust manifolds (A) by tightening the nuts as following method. (Refer to intake and exhaust system in this group)
Tightening torque :
49.0 ~ 53.9 N.m (5.0 ~ 5.5 kgf.m, 36.2 ~ 39.8 lb-ft)
   
The “TOP”mark of the gasket must be face the exhaust manifold.

   
Tighten the exhaust manifold nuts as followig method.
[RH]

[LH]

21.
Install the LH/RH exhaust manifold heat protectors (A).
Tightening torque :
8.8 ~ 10.8 N.m ( 0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)

22.
Install the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Engine coolant temperature sensor :
19.6 ~ 39.2 Nm (2.0 ~ 4.0 kgf.m, 14.5 ~ 28.9 lb-ft)

23.
Install the oil pressure switch (OPS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Oil pressure switch :
14.7 ~ 21.6 Nm ( 1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

24.
Use the SST (09231-2J510, 09231-H1100), install the oil seals (B) and the gaskets (A), fuel pump adapter gaskets (C).

25.
Install the LH/RH cylinder head covers.
(1)
The sealant locations on cylinder head and timing chain upper case must be free of engine oil and etc.
(2)
Before assembling the cylinder head cover, the liquid sealant LT5900H (Hyundai : Gray RTV) or equivalent should be applied on the gap between cylinder head and timing chain upper case.
The part must be assembled within 5 minutes after sealant was applied.

(3)
Install the LH/RH cylinder head covers (A).
The part must be assembled within 5 minutes after sealant was applied.
Tightening torque
1st step : 4.9 ~ 5.9 N.m (0.5 ~ 0.6 kgf.m, 3.6 ~ 4.3 lb-ft)
2nd step : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   
Tighten the cylinder head cover bolts as following method.
[RH]

[LH]

26.
Install the LH/RH fuel pumps (A).
(Refer to FL group)
Tightening torque :
12.7 ~ 14.7 N.m (1.3 ~ 1.5 kgf.m, 9.4 ~ 10.8 lb-ft)

27.
Install the LH/RH ignition coils (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

28.
Reconnect the water hose (A).

29.
Install the knock sensors (A) and wiring assembly brackets (B).
Tightening torque
Knock sensor :
14.7 ~ 24.5 N.m (1.5 ~ 2.5 kgf.m, 10.8 ~ 18.1 lb-ft)
LH bracket bolts :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
RH bracket & hanger bolts :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

30.
Install the injector & rail assembly (B) and cross over pipe (A).
(Refer to FL group)
Tightening torque
Rail assembly bolts :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Cross over pipe nuts :
26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)

31.
Install the LH/RH high pressure fuel pipes (A).
(Refer to FL group)
Tightening torque
Pipe bracket bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Pipe nuts :
26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)

32.
Install the low pressure fuel tube (A).
(Refer to FL group)

33.
Install the intake manifold module (A) by tightening the nuts as following method.
Tightening torque
1st step :
4.9 ~ 7.8N.m ( 0.5 ~ 0.8kgf.m, 3.6 ~ 5.8lb-ft)
2nd step :
19.6 ~ 26.5N.m ( 2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

   
Tighten the intake manifold nuts as followig method.

34.
Install the injector connector bracket bolt (C), high pressure fuel pipe bracket bolts (B)and the low pressure fuel tube bracket bolt (A) to the intake manifold module.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

35.
Install the oil level gauge (A).
Tightening torque :
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

36.
Connect the engine wiring harness connectors and hoses.
(1)
ETC module connector (A)
(2)
PCSV connector (B)
(3)
PCV hose (C)

(4)
Engine coolant temperature sensor (ECTS) connector (A)
(5)
RH intake oil control valve (OCV) connector (B)
(6)
RH exhaust oil control valve (OCV) connector (C)

(7)
Alternator connector (A)

(8)
RH ignition coil connectors (A)
(9)
RH fuel pump connector (B)
(10)
RH exhaust camshaft position sensor (CMPS) connector (C)
(11)
RH intake camshaft position sensor (CMPS) connector (D)

(12)
RH knock sensor connectors (A,B)
(13)
RH front oxygen sensor (HO2S) connector (C)
(14)
RH ignition coil condenser connector (D)
(15)
Ground (E)

(16)
Oil pressure switch (OPS) connector (A)
(17)
LH intake oil control valve (OCV) connector (B)
(18)
LH exhaust oil control valve (OCV) connector (C)
(19)
Compressor connector (D)

(20)
LH ignition coil connectors (A)
(21)
LH fuel pump connector (B)
(22)
LH intake camshaft position sensor (CMPS) connector (C)
(23)
LH exhaust camshaft position sensor (CMPS) connector (D)

(24)
LH knock sensor connectors (A,B)
(25)
Manifold absolute pressure (MAP) sensor connector (C)
(26)
Crankshaft position sensor (CKPS) connector (D)
(27)
LH ignition coil condenser connector (E)
(28)
LH front oxygen sensor (HO2S) connector (F)
(29)
Ground (G)
(30)
Injector connectors (H)

37.
Turn the tensioner (B) clockwise and loosen, then install the drive belt (A).

38.
Install the radiator & cooling fan assembly.
(Refer to Cooling system in this group)
39.
Connect the heater hoses (A),

40.
Connect the fuel hose (A), the purge control solenoid valve (PCSV) hose (B) and the brake booster vacuum hose (C).

41.
Connect the radiator upper hose (A) and lower hose (B).

42.
Install the air cleaner assembly.
(1)
Install the air cleaner assembly (E) and the chamber air clener (D).
Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
(2)
Connect the air intake hose to the throttle body and then tighten the clamp (C).
Tightening torque :
2.9 ~ 4.98 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
(3)
Reconnect the breather hose (B).
(4)
Install the air duct (A).

43.
Install the engine room cover (A), the engine cover (B) and the radiator grill upper cover (C).

44.
Connect the battery negative terminal (A).
Tightening torque :
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   
•
Refill engine oil.
•
Clean battery posts and cable terminals with sandpaper. Reassemble, then apply grease to prevent corrosion
•
Inspect for fuel leakage.
-
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
-
Repeat this operation two or three times, and then check for fuel leakage at any point in the fuel lines.
•
Refill radiator and reservoir tank with engine coolant.
•
Bleed air from the cooling system.
-
Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
-
Turn Off the engine and let it cool diwn. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
-
Put radiator cap on tightly, then run the engine again and check for leaks.
    Cylinder Head Components and Components Location
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