Hyundai Coupes/Sedans 1986-1993 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



Do not remove the cylinder head unless the engine is cold, a hot cylinder head will warp.

1468cc and 1495cc Engines

See Figures 1 through 7



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Fig. Fig. 1: Cylinder head bolt loosening sequence-1468cc engine



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Fig. Fig. 2: Cylinder head mounting-1468cc engine



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Fig. Fig. 3: Cylinder head bolt tightening sequence-1468cc engine



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Fig. Fig. 4: Cylinder head mounting-1495cc engine



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Fig. Fig. 5: Cylinder head bolt loosening sequence-1495cc engine



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Fig. Fig. 6: Cylinder head bolt tightening sequence-1495cc engine



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Fig. Fig. 7: Cylinder head gasket identification mark, usually a 2 digit number

  1. Release the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Drain the cooling system and then disconnect the upper radiator hose. Remove the PCV hose that runs between the air cleaner and the rocker cover.
  4.  
  5. Remove the air cleaner. Label and disconnect any vacuum lines running to the cylinder head, manifold or carburetor from other parts of the engine compartment. Disconnect the heater hoses going to the head.
  6.  
  7. Disconnect the fuel supply line, return line and vent hoses. Prior to disconnecting the fuel supply or return lines, wrap shop towels around the fitting that is being disconnected to absorb any fuel spray caused by residual pressure in the lines.
  8.  
  9. Label and disconnect the spark plug wires, injectors and any other electronic components that will be removed with the cylinder head. Remove the rocker cover. On turbocharged models, remove the air intake tube from the turbo.
  10.  
  11. Turn the crankshaft until the TDC timing marks align and both No. 1 cylinder valves are closed, both rockers are off the cams. The engine will now be at top dead center with No. 1 piston on its compression stroke.
  12.  
  13. Remove the distributor cap and matchmark the rotor tip to the distributor housing and the housing to the engine. Now, remove the distributor.
  14.  

With the distributor removed, do not crank the engine. If rotated with the distributor removed, the engine will have to be positioned with No. 1 cylinder at top dead center of its compression stroke prior to installing the distributor.

  1. Remove the carburetor, if equipped. Remove the intake and the exhaust manifolds.
  2.  
  3. Remove the timing belt cover. Note the location of the camshaft sprocket timing mark. Loosen both timing belt tensioner mounting bolts and move tensioner toward the water pump as far as it will go. Retighten the adjusting bolt to hold the tensioner in this position. Pull the timing belt off the camshaft sprocket but leave it engaged with the other sprockets.
  4.  

On 1498cc engines, a hex type socket is required to remove the head bolts.

  1. Loosen the head bolts in the proper sequence. When all have been loosened, remove them. Then, pull the head off the engine block, rocking it slightly to break it loose.
  2.  
  3. Inspect the head with a straightedge and a flat feeler gauge of 0.002 in. (0.05mm) thickness. The tolerance for warping of a used head is 0.002 in. (0.05mm). The block deck must be flat within the same tolerance. The height of the head should be 3.5 in. (89mm) with a maximum machining limit of 0.012 in. (0.3mm).
  4.  

To install:
  1. Clean the combustion chambers of carbon with a scraper that is not excessively sharp, being careful not to damage the aluminum surface. Sharp edges in the combustion chambers can cause detonation. Clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. The oil and water passages should be cleaned thoroughly. Also, blow compressed air through all the small oil passages to ensure that they are clear. Check that the EGR and air pump passages are also clear. Both gasket surfaces must be completely free of dirt.
  4.  
  5. Install a new head gasket, without sealant, and position the head on the cylinder block. Install all the bolts finger tight. Torque the bolts in sequence. First step to 15 ft. lbs. (20 Nm), 2nd step to 25 ft. lbs. (35 Nm). Then, torque again, in sequence, to 51-54 ft. lbs. (69-74 Nm).
  6.  
  7. Align the matchmarks and install the distributor to the engine.
  8.  
  9. Install the timing belt on the camshaft tensioner and rotate the camshaft sprocket backward so the belt is tight on what is normally the tension side. Make sure all the timing marks are now aligned. That is, timing marks on the crankshaft sprocket and front case must align; and the marks on the camshaft sprocket and the tab on the cylinder head must be simultaneously aligned with the side of the belt away from the tensioner under tension. Now, loosen the timing belt tensioner adjusting bolt and allow spring tension to tension the belt. Make sure all timing marks are still aligned. If not, the belt is out of time and must be shifted with the tensioner shifted back, toward the water pump and locked there. Now, torque the adjusting bolt on the right side, working through a slot, to 15-18 ft. lbs. (20-25 Nm). After the tensioner adjusting bolt is torqued, torque the hinged mounting bolt located on the opposite side. Don't torque the mounting bolt first or the tension on the belt will be too great.
  10.  
  11. Turn the crankshaft 1 full turn in the normal direction of rotation. Loosen first the tensioner pivot bolt and then the adjusting bolt. Now torque them exactly as before, adjusting bolt, working in the slot. This extra step is necessary to ensure the timing belt is properly seated before final tension is adjusted.
  12.  
  13. Install the cylinder head cover and tighten the bolts to 13-16 inch lbs. (1.5-2.0 Nm).
  14.  
  15. Install the timing belt cover.
  16.  
  17. Install the intake manifold using a new gasket and tighten the bolts and nut to 12-14 ft. lbs. (16-19 Nm).
  18.  
  19. Install the exhaust manifold using a new gasket and tighten the nuts to 12-14 ft. lbs. (16-19 Nm).
  20.  
  21. Install the carburetor or throttle body assembly.
  22.  
  23. Install the distributor. Connect all hoses, lines and the air cleaner.
  24.  
  25. Refill the cooling system. Operate the engine and check for leaks. After the engine has reached normal operating temperature, turn it off and remove the air cleaner and rocker cover. Retighten the cylinder head bolts to 58-61 ft. lbs. (78-83 Nm), in the sequence.
  26.  
  27. Reinstall the rocker cover and the air cleaner.
  28.  

2351cc Engine

See Figures 8, 9 and 10

  1. Disconnect the negative battery cable. Drain the engine coolant.
  2.  
  3. Remove the intake and exhaust manifolds.
  4.  



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Fig. Fig. 8: Cylinder head mounting-2351cc engine



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Fig. Fig. 9: Cylinder head bolt loosening sequence-2351cc engine



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Fig. Fig. 10: Cylinder head tightening sequence-2351cc engine

  1. Remove the air cleaner. Detach and tag all vacuum hoses, heater hoses and gauge connectors which connect with the cylinder head or would obstruct its removal.
  2.  
  3. Remove the throttle air valve.
  4.  
  5. Remove the timing belt cover.
  6.  
  7. Remove the rocker cover.
  8.  
  9. Rotate the crankshaft until the timing marks are at TDC with No. 1 cylinder at the firing position, front valves closed fully. If the rockers are not all the way off the cams, turn the engine another 360 degrees.
  10.  
  11. Label and disconnect all spark plug wires at the plugs.
  12.  
  13. Remove the distributor.
  14.  
  15. Remove the timing belt.
  16.  
  17. Using an 8mm hex socket, loosen the head bolts, in order, in 3 stages, alternating from bolt to bolt. Rock the head to break it loose and then remove the head and the gasket from the block.
  18.  
  19. Inspect the head with a straightedge and a flat feeler gauge of 0.10mm thickness. Run the gauge in every direction. The tolerance for warping of a used head is 0.05mm across the entire length. The block deck must be flat within the same tolerance. The refacing limit is 0.2mm. The overall head height should be 89.9-90.1mm.
  20.  

To install:
  1. Clean the combustion chambers of carbon with a scraper that is not excessively sharp and use it carefully to avoid damaging the relatively soft aluminum surface. Clean the gasket mating surfaces with a scraper and solvent.
  2.  
  3. The oil and water passages should be cleaned thoroughly, Blow compressed air through all the small oil passages to ensure that they are clear. Check that the EGR and air pump passages are also clear. Both gasket surfaces must be completely free of dirt.
  4.  
  5. Apply sealant around the 4 oil drain holes on the cylinder head gasket. Install the head gasket on the block deck, with the identification mark facing upward toward the cylinder head.
  6.  
  7. Put the head into position and install the head bolts. The bolts must be torqued to a cold specification, which is 65-72 ft. lbs. (88-98 Nm), in 3 stages. Using the proper sequence, torque the bolts, in order, to 25 ft. lbs. (34 Nm), 33-36 ft. lbs. (45-48 Nm). Then, repeat the operation, tightening them to the full torque of 72 ft. lbs. (98 Nm).
  8.  
  9. Perform the remaining steps in reverse of the removal procedure.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine, check for leaks and run the engine to normal operating temperature. Stop the engine. Remove the valve cover and torque the head bolts, warm, in sequence, to 72-80 ft. lbs. (96-108 Nm). Replace the valve cover.
  14.  

1596cc, 1796cc and 1997cc Engines

See Figures 11, 12 and 13

  1. Release the fuel system pressure. Disconnect the negative battery cable and drain the cooling system.
  2.  
  3. Disconnect the accelerator cable, PCV hoses, breather hoses, spark plug cables and remove the valve cover.
  4.  
  5. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. At this time the timing marks on the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the camshaft sprocket should be at the upper side.
  6.  

Always rotate the crankshaft in a clockwise direction. Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.

  1. Remove the timing belt upper and lower covers.
  2.  



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Fig. Fig. 11: Cylinder head mounting-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 12: Cylinder head bolt loosening sequence-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 13: Cylinder head bolt tightening sequence-1596cc, 1796cc and 1997cc engines

  1. Remove the timing belt.
  2.  
  3. Remove the crank angle sensor.
  4.  
  5. Loosen the cylinder head mounting bolts in 3 steps, starting from the outside and working inward. Lift off the cylinder head assembly and remove the head gasket.
  6.  

To install:
  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean oil passages thoroughly. Check the head for flatness. End to end, the head should be within 0.002 in. normally, with 0.008 in. the maximum allowed out of true. The total thickness allowed to be removed from the head and block is 0.008 in. maximum.
  2.  
  3. Place a new head gasket on the cylinder block with the identification marks at the front top (upward) position. Make sure the gasket has the proper identification mark for the engine. Do not use sealer on the gasket.
  4.  
  5. Carefully install the cylinder head on the block. Using 3 even steps, torque the head bolts in sequence to 76-83 ft. lbs. (105-115 Nm) on 1997cc engine. On 1596cc and 1796cc engines, torque the head bolts in sequence to 65-72 ft. lbs. (90-100 Nm) using 3 even steps. These torques apply to a cold engine.
  6.  
  7. Install the timing belt and all related items.
  8.  
  9. Align the punch mark on the crank angle sensor housing with the notch on the plate. Install the crank angle sensor into the cylinder head.
  10.  

The crank angle sensor can be installed even when the punch mark is positioned opposite the notch; however, the position results in incorrect fuel injection and ignition timing.

  1. Apply sealer to the perimeter of the half-round seal and to the lower edges of the half-round portions of the belt-side of the new gasket. Install the valve cover.
  2.  
  3. Connect or install all previously disconnected hoses, cables and electrical connections. Adjust the throttle cable(s).
  4.  
  5. Install the spark plug cable center cover.
  6.  
  7. Replace the O-rings and connect the fuel lines.
  8.  
  9. Install the air cleaner and intake hose. Connect the breather hose.
  10.  
  11. Change the engine oil and oil filter.
  12.  
  13. Fill the system with coolant. Connect the negative battery cable, run the vehicle until the thermostat opens and fill the radiator completely.
  14.  
  15. Check and adjust the idle speed and ignition timing.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level.
  18.  

2972cc Engine

See Figures 14, 15 and 16

  1. Relieve the fuel pressure. Disconnect the negative battery cable. Drain the cooling system.
  2.  



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Fig. Fig. 14: Cylinder head bolt loosening sequence-2972cc engine



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Fig. Fig. 15: Cylinder head bolt tightening sequence-2972cc engine



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Fig. Fig. 16: On the 2972cc engine, install the cylinder head gasket so that the identification mark is UP

  1. Remove the compressor drive belt and the air conditioning compressor from its mount and support it aside. Using a 1 / 2 in. drive breaker bar, insert it into the square hole of the serpentine drive belt tensioner, rotate it counterclockwise to reduce the belt tension and remove the belt. Remove the alternator and power steering pump from the brackets and move them aside.
  2.  
  3. Raise the vehicle and support safely. Remove the right front wheel and the inner splash shield.
  4.  
  5. Remove the crankshaft pulleys and the torsional damper.
  6.  
  7. Lower the vehicle. Using a floor jack and a block of wood positioned under the oil pan, raise the engine slightly. Remove the engine mount bracket from the timing cover end of the engine and the timing belt covers.
  8.  
  9. To remove the timing belt, perform the following procedures:
    1. Rotate the crankshaft to position the No. 1 cylinder on TDC of its compression stroke; the crankshaft sprocket timing mark should align with the oil pan timing indicator and the camshaft sprocket timing marks (triangles) should align with the rear timing belt cover timing marks.
    2.  
    3. Mark the timing belt in the direction of rotation for reinstallation purposes.
    4.  
    5. Loosen the timing belt tensioner and remove the timing belt.
    6.  

  10.  

When removing the timing belt from the camshaft sprocket, make sure the belt does not slip off of the other camshaft sprocket. Support the belt so it cannot slip off of the crankshaft sprocket and opposite side camshaft sprocket.

  1. Remove the air cleaner assembly. Label and disconnect the spark plug wires and the vacuum hoses.
  2.  
  3. Remove the valve cover.
  4.  
  5. Install auto lash adjuster retainer tools MD998443 or equivalent, on the rocker arms.
  6.  
  7. If removing the front cylinder head, matchmark the distributor rotor to the distributor housing and the housing to distributor extension locations. Remove the distributor and the distributor extension.
  8.  
  9. Remove the camshaft bearing assembly to cylinder head bolts but do not remove the bolts from the assembly. Remove the rocker arms, rocker shafts and bearing caps as an assembly, as required. Remove the camshafts from the cylinder head and inspect them for damage.
  10.  
  11. Remove the intake manifold assembly.
  12.  
  13. Remove the exhaust manifold.
  14.  
  15. Remove the cylinder head bolts, starting from the outside and working inward. Remove the cylinder head from the engine.
  16.  
  17. Clean the gasket mounting surfaces and check the heads for warpage; maximum warpage is 0.008 in. (0.20mm).
  18.  

To install:
  1. Install the new cylinder head gasket over the dowels on the engine block.
  2.  
  3. Install the cylinder head(s) on the engine and torque the cylinder head bolts, in sequence, using 3 even steps, to 70 ft. lbs. (95 Nm).
  4.  
  5. Install or connect all items that were removed or disconnected during the removal procedure.
  6.  
  7. When installing the timing belt on the camshaft sprocket, use care not to allow the belt to slip off the opposite camshaft sprocket.
  8.  
  9. Make sure the timing belt is installed on the camshaft sprocket in the same position as when removed.
  10.  
  11. Refill the cooling system. Connect the negative battery cable. Start the engine and check for leaks using the DRB I or II to activate the fuel pump.
  12.  
  13. Adjust the timing, as required.
  14.  

 
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