Hyundai Coupes/Sedans 1994-1998 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



See Figures 1 through 9



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Fig. Fig. 1: Remove the upper timing belt cover....



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Fig. Fig. 2: ....and ensure the timing belt marks are aligned....



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Fig. Fig. 3: .....then, remove the timing belt



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Fig. Fig. 4: Remove the rocker cover....



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Fig. Fig. 5: ....and loosen the head bolts in the proper sequence. The cylinder head must be cold prior to removal



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Fig. Fig. 6: Carefully remove the cylinder head....



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Fig. Fig. 7: ....and the head gasket



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Fig. Fig. 8: Clean the cylinder head and engine block of old gasket material using a scraper



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Fig. Fig. 9: Install the cylinder head and torque head bolts to specification using the proper torque sequence

The cylinder heads are made of aluminum. Do not remove the cylinder head unless the engine is cold. A hot cylinder head will warp once removed from the engine.

Except 3.0L (VIN T) Engine

See figures 10, 11, 12 and 13

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Fig. Fig. 10: Cylinder head bolt loosen and tighten sequence-1.5L (VIN E) engine



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Fig. Fig. 11: Cylinder head bolt loosen and tighten sequence-1.5L (VIN J) engine



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Fig. Fig. 12: Cylinder head bolt loosen and tighten sequence-1.5L (VIN K), 1.6L (VIN R), 2.0L (VIN F) and 1996-98 1.8L (VIN M) engines



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Fig. Fig. 13: Cylinder head bolt loosen and tighten sequence-2.0L (VIN P) and 1994-95 1.6L (VIN R) and 1.8L (VIN M) engines

  1. Properly release fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the upper radiator hose and heater hoses.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Label and disconnect any vacuum lines running to the cylinder head.
  12.  
  13. Label and disconnect any electrical harnesses running to the cylinder head.
  14.  
  15. Label and disconnect the spark plug wires.
  16.  
  17. Turn the crankshaft until the No. 1 cylinder is at TDC on the compression stroke.
  18.  
  19. Remove the distributor or ignition coil pack.
  20.  
  21. Remove the power steering oil pump and bracket.
  22.  
  23. Remove the intake and exhaust manifolds.
  24.  
  25. Remove the water pump and crankshaft pulleys.
  26.  
  27. Remove the timing belt covers.
  28.  
  29. Remove the timing belt.
  30.  

Do not rotate the engine with the timing belt removed.

  1. Remove the rocker cover.
  2.  
  3. Loosen the cylinder head bolts in proper sequence.
  4.  
  5. Carefully remove the cylinder head from the engine.
  6.  

To install:
  1. The cylinder head should be disassembled, cleaned and inspected prior to installation. If you do not feel confident performing the inspection procedures, then take the cylinder head to a competent machinist.
  2.  
  3. Install the cylinder head using a new head gasket. Tighten head bolts to proper torque specification in sequence.

    2.0L (VIN F) and 1996-98 1.8L (VIN M) engines-Tighten M10 bolts to 22 ft. lbs. (30 Nm), plus 60°-65°, plus 60°-65°. Tighten M12 bolts to 26 ft. lbs. (35 Nm), plus 60°-65°, plus 60°-65°.
     
    1.5L (VIN E), 1.5L (VIN J) and 1.5L (VIN K) engines-51-54 ft. lbs. (71-75 Nm).
     
    1.6L (VIN F), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines-65-72 ft. lbs. (90-100 Nm).
     

  4.  
  5. Install the rocker cover.
  6.  
  7. Ensure the No. 1 cylinder is still TDC on the compression stroke.
  8.  
  9. Align the timing marks on the cylinder head and camshaft gear.
  10.  
  11. Install and properly tension the timing belt.
  12.  
  13. Install the timing belt covers.
  14.  
  15. Install the water pump and crankshaft pulleys.
  16.  
  17. Install the intake and exhaust manifolds.
  18.  
  19. Install the power steering oil pump and bracket.
  20.  
  21. Install the distributor or ignition coil pack.
  22.  
  23. Connect the spark plug wires.
  24.  
  25. Connect any electrical harnesses running to the cylinder head.
  26.  
  27. Connect any vacuum lines running to the cylinder head.
  28.  
  29. Install the air cleaner assembly.
  30.  
  31. Connect the upper radiator hose and heater hoses.
  32.  
  33. Refill the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  38.  
  39. Adjust the ignition timing, as required.
  40.  
  41. Once the vehicle has cooled, recheck the coolant level.
  42.  

3.0L (VIN T) Engine

See Figure 14



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Fig. Fig. 14: Cylinder head bolt loosen and tighten sequence-3.0L (VIN T) engine

  1. Properly release fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the air conditioning compressor.
  8.  
  9. Remove the alternator and power steering pump.
  10.  
  11. Remove the timing belt covers.
  12.  
  13. Rotate the crankshaft to position the No. 1 cylinder on TDC of its compression stroke.
  14.  

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.

  1. Remove the timing belts.
  2.  

Do not rotate the engine with the timing belt removed.

  1. Remove the air cleaner assembly.
  2.  
  3. Label and disconnect any vacuum lines running to the cylinder head.
  4.  
  5. Label and disconnect any electrical harnesses running to the cylinder head.
  6.  
  7. Label and disconnect the spark plug wires.
  8.  
  9. Remove the rocker covers.
  10.  
  11. Remove the distributor.
  12.  
  13. Remove the intake manifold assembly.
  14.  
  15. Remove the exhaust manifolds.
  16.  
  17. Loosen the cylinder head bolts in proper sequence.
  18.  
  19. Carefully remove the cylinder head from the engine.
  20.  

To install:
  1. The cylinder head should be disassembled, cleaned and inspected prior to installation. If you do not feel confident performing the inspection procedures, then take the cylinder head to a competent machinist.
  2.  
  3. Install the cylinder head using a new head gasket. Tighten head bolts in sequence to 76-83 ft. lbs. (105-115 Nm).
  4.  
  5. Install the exhaust manifolds.
  6.  
  7. Install the intake manifold assembly.
  8.  
  9. Install the distributor.
  10.  
  11. Install the rocker covers.
  12.  
  13. Connect the spark plug wires.
  14.  
  15. Connect any electrical harnesses running to the cylinder head.
  16.  
  17. Connect any vacuum lines running to the cylinder head.
  18.  
  19. Install the air cleaner assembly.
  20.  

Prior to installing the timing belt, check the timing marks for proper alignment. 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.

  1. Install and tension the timing belts.
  2.  
  3. Install the timing belt covers.
  4.  
  5. Install the alternator and power steering pump.
  6.  
  7. Install the air conditioning compressor.
  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  14.  
  15. Adjust the ignition timing.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level.
  18.  

 
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