Hyundai Car 1999-05

Cylinder Head

Print

Removal & Installation



2.5L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake assembly
     
    A/C compressor
     
    Alternator
     
    Power steering pump
     
    Front covers
     
    Timing belt
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Spark plug wires
     
    Distributor
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifolds
     
    Valve cover bolts
     
    Cylinder heads by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

  1. Install or connect the following:

    New head gaskets
     
    Cylinder heads
     

  2.  
  3. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
  4.  
  5. For 2.5L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Plus 60-64 degree turn.
    4.  
    5. Step 3: Plus 45-49 degree turn.
    6.  

  6.  
  7. Install or connect the following:

    Valve covers
     
    Exhaust manifolds
     
    Intake manifold
     
    Fuel lines
     
    Distributor
     
    Spark plug wires
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Timing belt and front covers
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Air intake assembly
     
    Accessory drive belts
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Breather hose
     
    Air intake hose
     
    Vacuum hose
     
    Fuel hoses
     
    Intake manifold
     
    Spark plug wires
     
    Ignition coil
     
    Upper and lower timing belt covers
     
    Timing belt
     
    Camshaft sprockets
     
    Heat protector and exhaust manifold
     
    Water pump
     
    Rocker arm cover
     
    Camshafts
     
    Cylinder head and discard the gasket
     

  8.  
  9. Clean all mating surfaces of any residual gasket material.
  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L XG300 Engine

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
     
    Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)
     
    Camshafts
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Camshaft sprockets
     
    Timing belt
     
    Upper and lower timing belt covers
     
    Ignition coil and spark plug wires
     
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Fuel hoses
     
    Vacuum hose
     
    Air intake hose
     
    Breather hose
     
    Upper radiator hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Breather hose
     
    Air intake hose
     
    Vacuum hose
     
    Fuel hoses
     
    Intake manifold
     
    Spark plug wires
     
    Ignition coil
     
    Upper and lower timing belt covers
     
    Timing belt
     
    Camshaft sprockets
     
    Heat protector and exhaust manifold
     
    Water pump
     
    Rocker arm cover
     
    Camshafts
     

  8.  
  9. The cylinder head bolts should be loosened in sequence as shown.
  10.  
  11. Remove the cylinder head and discard the gasket.
  12.  
  13. Clean all mating surfaces of any residual gasket material. Cylinder head loosening sequence-3.5L engine
  14.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.5L engine

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
     
    Cylinder head and torque the bolts in sequence to 82 ft. lbs. (115 Nm)
     
    Camshafts
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Camshaft sprockets
     
    Timing belt
     
    Upper and lower timing belt covers
     
    Ignition coil and spark plug wires
     
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Fuel hoses
     
    Vacuum hose
     
    Air intake hose
     
    Breather hose
     
    Upper radiator hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

4-Cylinder Engines


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Heater hose
     
    Air cleaner assembly
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Spark plug wires
     
    Distributor, if equipped
     
    Ignition coil
     
    Accessory drive belts
     
    Power steering pump and bracket
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifold
     
    Front cover
     
    Timing belt
     
    Valve cover bolts
     
    Cylinder head by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  4.  
  5. For 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: Plus 60-65 degrees.
    4.  
    5. Step 3: Plus 60-65 degrees.
    6.  

  6.  
  7. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  8.  
  9. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen all bolts in reverse of tightening order.
    6.  
    7. Step 4: 14 ft. lbs. (20 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  10.  
  11. Install or connect the following:

    Valve cover
     
    Timing belt and front cover
     
    Exhaust manifold
     
    Intake manifold
     
    Fuel lines
     
    Power steering pump and bracket
     
    Accessory drive belts
     
    Ignition coil
     
    Distributor, if equipped
     
    Spark plug wires
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Air cleaner assembly
     
    Heater hose
     
    Upper radiator hose
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Heater hose
     
    Air cleaner assembly
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Spark plug wires
     
    Distributor, if equipped
     
    Ignition coil
     
    Accessory drive belts
     
    Power steering pump and bracket
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifold
     
    Front cover
     
    Timing belt
     
    Valve cover bolts
     
    Cylinder head by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  4.  
  5. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
  6.  
  7. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: Plus 60-65 degrees.
    4.  
    5. Step 3: Plus 60-65 degrees.
    6.  

  8.  
  9. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  10.  
  11. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen all bolts in reverse of tightening order.
    6.  
    7. Step 4: 14 ft. lbs. (20 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  12.  
  13. Install or connect the following:

    Valve cover
     
    Timing belt and front cover
     
    Exhaust manifold
     
    Intake manifold
     
    Fuel lines
     
    Power steering pump and bracket
     
    Accessory drive belts
     
    Ignition coil
     
    Distributor, if equipped
     
    Spark plug wires
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Air cleaner assembly
     
    Heater hose
     
    Upper radiator hose
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
  16.  
  17. Start the engine and check for leaks.
  18.  



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-1.5L, 1.6L, 1.8L, Elantra and Tiburon 2.0L engines



Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-Sonata 2.0L and 2.4L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Heater hose
     
    Air cleaner assembly
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Spark plug wires
     
    Distributor, if equipped
     
    Ignition coil
     
    Accessory drive belts
     
    Power steering pump and bracket
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifold
     
    Front cover
     
    Timing belt
     
    Valve cover bolts
     
    Cylinder head by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.5L, 1.8L and Elantra and Tiburon 2.0L Engines



Click image to see an enlarged view

Fig. Cylinder head torque sequence-Sonata 2.0L and 2.4L Engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. For 1.5L engines, tighten the bolts in sequence to 51-54 ft. lbs. (71-75 Nm).
  4.  
  5. For 1.6L engines, tighten the bolts, in sequence, to 26 ft. lbs. (35 Nm) plus 75 degrees. Loosen the bolts and retorque to 26 ft. lbs. (35 Nm) plus 75 degrees.
  6.  
  7. For 1.8L and 2.0L Elantra and Tiburon engines, tighten the bolts in sequence as follows:
    1. Step 1: M10 bolts to 22 ft. lbs. (30 Nm) and M12 bolts to 26 ft. lbs. (35 Nm).
    2.  
    3. Step 2: Plus 60-65 degrees.
    4.  
    5. Step 3: Plus 60-65 degrees.
    6.  

  8.  
  9. For Sonata 2.0L engines, tighten the bolts in sequence to 65-72 ft. lbs. (90-100 Nm).
  10.  
  11. For 2.4L engines, tighten the bolts in sequence as follows:
    1. Step 1: 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen all bolts in reverse of tightening order.
    6.  
    7. Step 4: 14 ft. lbs. (20 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  12.  
  13. Install or connect the following:

    Valve cover
     
    Timing belt and front cover
     
    Exhaust manifold
     
    Intake manifold
     
    Fuel lines
     
    Power steering pump and bracket
     
    Accessory drive belts
     
    Ignition coil
     
    Distributor, if equipped
     
    Spark plug wires
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Air cleaner assembly
     
    Heater hose
     
    Upper radiator hose
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
  16.  
  17. Start the engine and check for leaks.
  18.  

V6 Engine
2.5L And 2.7L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L and 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake assembly
     
    A/C compressor
     
    Alternator
     
    Power steering pump
     
    Front covers
     
    Timing belt
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Spark plug wires
     
    Distributor
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifolds
     
    Valve cover bolts
     
    Cylinder heads by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

  1. Install or connect the following:

    New head gaskets
     
    Cylinder heads
     

  2.  
  3. For 2.5L and 2.7L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Plus 60-64 degree turn.
    4.  
    5. Step 3: Plus 45-49 degree turn.
    6.  

  4.  
  5. Install or connect the following:

    Valve covers
     
    Exhaust manifolds
     
    Intake manifold
     
    Fuel lines
     
    Distributor
     
    Spark plug wires
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Timing belt and front covers
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Air intake assembly
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

2.5L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence-2.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake assembly
     
    A/C compressor
     
    Alternator
     
    Power steering pump
     
    Front covers
     
    Timing belt
     
    Engine control wiring harness connectors
     
    Intake manifold vacuum lines
     
    Spark plug wires
     
    Distributor
     
    Fuel lines
     
    Intake manifold
     
    Exhaust manifolds
     
    Valve cover bolts
     
    Cylinder heads by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 3.0L Sonata

  1. Install or connect the following:

    New head gaskets
     
    Cylinder heads
     

  2.  
  3. For 3.0L engines, tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
  4.  
  5. For 2.5L engines, tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Plus 60-64 degree turn.
    4.  
    5. Step 3: Plus 45-49 degree turn.
    6.  

  6.  
  7. Install or connect the following:

    Valve covers
     
    Exhaust manifolds
     
    Intake manifold
     
    Fuel lines
     
    Distributor
     
    Spark plug wires
     
    Intake manifold vacuum lines
     
    Engine control wiring harness connectors
     
    Timing belt and front covers
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Air intake assembly
     
    Accessory drive belts
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

2.7L Engine


Click image to see an enlarged view

Fig. Cylinder head bolt loosening sequence- 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Air intake assembly
     
    Radiator and heater hoses
     
    Engine control wiring harness connectors
     
    Fuel lines
     
    Brake booster vacuum hose
     
    Power steering pump
     
    Front covers
     
    Timing belt
     
    Intake manifold vacuum lines
     
    Ignition coil
     
    Intake manifold
     
    Exhaust manifolds
     
    Valve covers
     
    Camshafts
     
    Timing belt rear cover
     
    Cylinder heads by loosening the bolts in sequence
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.5L and 2.7L Sonata

  1. Install or connect the following:

    New head gaskets
     
    Cylinder heads
     

  2.  
  3. Tighten the bolts in sequence as follows:
    1. Step 1: 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Plus 60-64 degree turn.
    4.  
    5. Step 3: Plus 45-49 degree turn.
    6.  

  4.  
  5. Install or connect the following:

    Timing belt rear cover. Tighten to 7-9 ft. lbs. (10-12 Nm).
     
    Camshafts
     
    Valve covers
     
    Timing belt
     
    Exhaust manifolds
     
    Power steering pump
     
    Intake manifold
     
    Brake booster vacuum hose
     
    Fuel lines
     
    Ignition coil
     
    Engine control wiring harness connectors
     
    Radiator and heater hoses
     
    Spark plug wires
     
    Air intake assembly
     
    Accessory drive belts
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

3.0L And 3.5L And 3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Breather hose
     
    Air intake hose
     
    Vacuum hose
     
    Fuel hoses
     
    Intake manifold
     
    Spark plug wires
     
    Ignition coil
     
    Upper and lower timing belt covers
     
    Timing belt
     
    Camshaft sprockets
     
    Heat protector and exhaust manifold
     
    Water pump
     
    Rocker arm cover
     
    Camshafts
     
    Cylinder head and discard the gasket
     

  8.  
  9. Clean all mating surfaces of any residual gasket material.
  10.  

To install:



Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L and 3.5L engines

  1. Install or connect the following:

    New gasket with the identification mark facing the cylinder head
     
    Cylinder head and torque the bolts, in sequence, to 82 ft. lbs. (115 Nm)
     
    Camshafts
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Heat protector and exhaust manifold and torque the bolts to 14 ft. lbs. (19 Nm)
     
    Camshaft sprockets
     
    Timing belt
     
    Upper and lower timing belt covers
     
    Ignition coil and spark plug wires
     
    Intake manifold and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Fuel hoses
     
    Vacuum hose
     
    Air intake hose
     
    Breather hose
     
    Upper radiator hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
label.common.footer.alt.autozoneLogo