Hyundai Cars 2006-2008

Valve Covers

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Removal & Installation



Specific to:

Hyundai Entourage 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Use fender covers to avoid damaging painted surfaces.


    WARNING
    To avoid damage, unplug the wiring connectors carefully while holding the connector portion.


    NOTE
    Mark all wiring and hoses to avoid misconnection.

  2.  
  3. Disconnect the negative terminal from the battery.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air duct.
  8.  
  9. Remove the intake air hose and air cleaner assembly.
    1. Disconnect the AFS connector (A).
    2.  
    3. Disconnect the breather hose (B) from air cleaner hose.
    4.  
    5. Disconnect the ECM connector.
    6.  
    7. Remove the intake air hose (C) and air cleaner (D).

      Click image to see an enlarged view

      Fig. Remove the intake air hose and air cleaner assembly

    8.  

  10.  
  11. Remove the RH front wheel.
  12.  
  13. Remove the undercover.
  14.  
  15. Remove the RH side cover.
  16.  
  17. Drain the engine coolant. Remove the radiator cap to speed draining.
  18.  
  19. Remove the upper radiator hose.
  20.  
  21. Drain the engine oil.
  22.  
  23. Remove the lower oil pan. Refer to Oil Pan, removal & installation.
  24.  
  25. Place a jack underneath the upper oil pan.
  26.  
  27. Just loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B).

    Click image to see an enlarged view

    Fig. Loosen the transaxle mounting bolts (A) without removing the transaxle mounting (B)

  28.  
  29. Remove the engine coolant reservoir tank (A).
  30.  
  31. Remove the engine mounting bracket (B).

    Click image to see an enlarged view

    Fig. Remove the engine coolant reservoir tank (A) and the engine mounting bracket (B)

  32.  
  33. Loosen the A/C pipe bracket mounting bolt.
  34.  
  35. Remove the No. 1 engine mounting (A) through the lower position of the A/C pipe line.

    Click image to see an enlarged view

    Fig. Remove the No. 1 engine mounting (A) through the lower position of the A/C pipe line

  36.  
  37. Remove the surge tank and engine wiring.
    1. Disconnect the RH oxygen sensor connector.
    2.  
    3. Disconnect the VIS solenoid valve connector.
    4.  
    5. Disconnect the power steering oil pressure sensor connector.
    6.  
    7. Disconnect the RH injector connector and the ignition coil connector.
    8.  
    9. Disconnect the OCV connector and knock sensor connector.
    10.  
    11. Disconnect the LH front oxygen sensor connector, alternator connector, and air compressor connector.
    12.  
    13. Disconnect the LH ignition coil connector, injector connector, condenser connector, and ground
    14.  
    15. Remove the wiring harness protector.
    16.  
    17. Disconnect the LH CMPS and oil pressure switch connector.
    18.  
    19. Disconnect the ETC connector and the knock sensor connector.
    20.  
    21. Disconnect the PCSV connector, the MAP sensor connector, and the PCSV hose.
    22.  
    23. Remove the Electronic Throttle Control (ETC) bracket.
    24.  
    25. Disconnect the water hoses from the ETC.
    26.  
    27. Disconnect the PCV hose.
    28.  
    29. Disconnect the brake vacuum hose.
    30.  
    31. Remove the surge tank stay.
    32.  
    33. Remove the connector bracket from the surge tank.
    34.  
    35. Remove the surge tank (A).
      NOTE
      Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.



      Click image to see an enlarged view

      Fig. Remove the surge tank (A)

    36.  

  38.  
  39. Remove the valve cover(s), also called cylinder head cover(s).
    1. Remove the connector bracket (A) from the LH cylinder head cover.
    2.  
    3. Disconnect the RH ignition coil connector(A), the condenser connector (B) and remove the wiring bracket (C).

      Click image to see an enlarged view

      Fig. Remove the connector bracket (A) from the LH cylinder head cover

    4.  
    5. Remove the LH and RH ignition coils.
    6.  
    7. Remove the LH and RH cylinder head covers.
      NOTE
      Cover the upside of engine head with a clean vinyl cover to prevent foreign materials from entering.

    8.  

  40.  

To install:

  1. Install the valve cover, also called cylinder head cover.
    1. The sealant located on the upper area between the timing chain cover and the cylinder head should be removed before assembling the cylinder head cover.
    2.  
    3. After applying sealant (TB1217H), it should be assembled within 5 minutes. Bead width: 0.1 inch (2.5mm).
    4.  
    5. Wait 30 minutes after the cylinder head cover was assembled before starting the engine.
    6.  
    7. Install the cylinder head cover bolts as shown in the illustration. Tightening torque: 87-104 inch lbs. (10-12 Nm).
      NOTE
      Do not reuse the cylinder head cover gasket.



      Click image to see an enlarged view

      Fig. Tighten the cylinder head cover bolts in the sequence shown

    8.  

  2.  
  3. Install the ignition coils.
  4.  
  5. Connect the RH ignition coil connector, the condenser connector, and install the wiring bracket.
  6.  
  7. Install the connector bracket from the LH cylinder head cover.
  8.  
  9. Install the surge tank. Tightening torque: 87-104 inch lbs. (10-12 Nm).
    1. Install the connector bracket(A) on the surge tank. Tightening torque: 210-224 ft. lbs. (284-304 Nm).
    2.  
    3. Install the surge tank stay. Tightening torque: 20-23 ft. lbs. (27-31 Nm).
    4.  

  10.  
  11. Connect the brake vacuum hose.
  12.  
  13. Connect the PCV hose.
  14.  
  15. Connect the water hoses to the ETC.
  16.  
  17. Install the ETC bracket. Tightening torque: 12-19 ft. lbs. (16-26 Nm).
  18.  
  19. Connect the PCSV connector, the MAP sensor connector, and the PCSV hose.
  20.  
  21. Connect the ETC connector and the knock sensor connector.
  22.  
  23. Connect the LH CMPS and oil pressure switch connector.
  24.  
  25. Install the wiring harness protector, and connect the LH ignition connector, injector connector, condenser connector, and ground.
  26.  
  27. Connect the OCV connector and knock sensor connector.
  28.  
  29. Connect the LH front oxygen sensor connector, alternator connector, and air compressor connector.
  30.  
  31. Connect the RH injector connector and the ignition coil connector.
  32.  
  33. Connect the power steering oil pressure sensor connector.
  34.  
  35. Connect the RH oxygen sensor connector and VIS solenoid valve connector.
  36.  
  37. Connect the RH oxygen sensor connector.
  38.  
  39. Install the No. 1 engine mounting through the lower position of A/C pipe line. Tightening torque: 36-47 ft. lbs. (49-64 Nm).
  40.  
  41. Install the A/C pipe bracket mounting bolt.
  42.  
  43. Install the engine coolant reservoir tank.
  44.  
  45. Install the engine mounting bracket. Tightening torque: 47-62 ft. lbs. (64-83 Nm).
  46.  
  47. Install the transaxle mounting bolts. Tightening torque: 36-47 ft. lbs. (49-64 Nm).
  48.  
  49. Remove the jack from the upper oil pan.
  50.  
  51. Install the lower oil pan. Refer to Oil Pan, removal & installation. Uniformly tighten the bolts in several passes. Tightening torque: 87-104 inch lbs. (10-12 Nm).
  52.  
  53. Install the upper radiator hose.
  54.  
  55. Install the side cover.
  56.  
  57. Install the undercover.
  58.  
  59. Install the front wheel(s).
  60.  
  61. Install the intake air hose and air cleaner assembly.
    1. Install the intake air hose and air cleaner.
    2.  
    3. Connect the ECM connector.
    4.  
    5. Connect the breather hose to air cleaner hose.
    6.  
    7. Connect the AFS connector.
    8.  
    9. Install the air duct.
    10.  

  62.  
  63. Install the engine cover.
  64.  
  65. Connect the negative terminal to the battery.
  66.  
  67. Refill the engine with the proper amount and type of engine oil.
  68.  
  69. Refill the radiator and reservoir tank with engine coolant.
  70.  
  71. Bleed the air from the cooling system.
  72.  
  73. Run the engine and check for leaks.
  74.  

Specific to:

Hyundai Accent 2006-2008

Hyundai Azera 2006-2008

Hyundai Elantra 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008


WARNING
Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.


NOTE
Mark all wiring and hoses to avoid misconnection.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the air duct.
  4.  
  5. Disconnect the negative terminal from the battery.
  6.  
  7. Remove the engine cover.
  8.  
  9. Disconnect the AFS connector.
  10.  
  11. Remove the Positive Crankcase Ventilation (PCV) hose and breather hose.
  12.  
  13. Disconnect the breather hose from air cleaner hose.
  14.  
  15. Remove the intake air hose and air cleaner assembly.
  16.  
  17. Remove the ignition coils. Refer to Ignition Coil Pack, removal & installation.
  18.  
  19. Remove the valve cover (also called cylinder head cover).
  20.  
  21. Remove the valve cover gasket and thoroughly clean the cylinder head surface, where the gasket rests, and the valve cover.

    Click image to see an enlarged view

    Fig. Valve cover with gasket removed

  22.  

To install:


NOTE
Before installing the valve cover gasket, thoroughly clean the gasket and the groove.


NOTE
When installing, make sure the valve cover gasket is seated securely in the corners of the recesses with no gap.

  1. Install the valve cover gasket (A) in the groove of the valve cover (B).
  2.  
  3. Apply liquid gasket to the valve cover gasket at the corners of the recess.
    NOTE
    Use liquid gasket-Loctite® No. 5999.



    Click image to see an enlarged view

    Fig. Valve cover liquid gasket placement

  4.  
  5. Check that the mating surfaces are clean and dry before applying liquid gasket.
  6.  
  7. Install the valve cover (A) with the 12 bolts (B).
  8.  
  9. Uniformly tighten the bolts in several passes. Tightening torque: 6-7 ft. lbs. (8-10 Nm).

    Click image to see an enlarged view

    Fig. Alignment of valve cover mounting

  10.  
  11. Install the ignition coils. Refer to Ignition Coil Pack, removal & installation.
  12.  
  13. Connect the breather hose from air cleaner hose.
  14.  
  15. Install the PCV hose and breather hose.
  16.  
  17. Connect the AFS connector.
  18.  
  19. Install the intake air hose and air cleaner assembly.
  20.  
  21. Install the engine cover.
  22.  
  23. Connect the negative battery cable to the negative battery terminal.
  24.  
  25. Install the air duct.
  26.  

 
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