Hyundai Coupes/Sedans 1994-1998 Repair Guide

Rocker Cover

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REMOVAL & INSTALLATION



See Figures 1 through 10



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Fig. Fig. 1: To remove the rocker cover, first label and disconnect the spark plug wires....



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Fig. Fig. 2: ....disconnect the PCV hose....



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Fig. Fig. 3: ....and the breather hose



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Fig. Fig. 4: On some models, the accelerator cable clips onto the valve cover and must be released



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Fig. Fig. 5: Remove the upper timing belt cover....



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Fig. Fig. 6: ....then loosen the attaching bolts and remove the rocker cover



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Fig. Fig. 7: Inspect the pan rail carefully and straighten as necessary. Always use a new gasket

1.5L (VIN E), 1.5L (VIN J) and 1.5L (VIN K) Engines
  1. Remove the air intake hose, as necessary.
  2.  
  3. Label and remove the spark plug wires.
  4.  
  5. Remove the breather and PCV hoses.
  6.  
  7. Remove the upper timing belt cover.
  8.  
  9. Remove the rocker cover.
  10.  

To Install:
  1. Clean all rocker cover gasket mating surfaces.
  2.  
  3. Inspect the breather and PCV ports, camshaft end seal and valve cover end seals. Repair or replace as necessary.
  4.  



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Fig. Fig. 8: Apply a 0.4 in. (10 mm) bead of Three Bond No. 1212Dor equivalent sealant to each end of the rocker coveras illustrated-1.5L (VIN E), 1.5L (VIN J), 1.5L (VIN K) and 3.0L (VIN P) engines

  1. Apply a 0.4 in. (10 mm) bead of Three Bond No. 1212D or equivalent sealant to the top surface of the cylinder head and cam cap. Refer to illustration for specific application points.
  2.  
  3. Install the rocker cover and tighten bolts to 1.0-1.5 ft. lbs. (1.5-2.0 Nm).
  4.  

Do not overtighten the valve cover bolts, because warpage of the valve cover and oil leakage could result.

  1. Install the upper timing belt cover and tighten bolts to 7-8 ft. lbs. (10-12 Nm).
  2.  
  3. Install the breather and PCV hoses.
  4.  
  5. Install the spark plug wires.
  6.  
  7. Install the air intake hose.
  8.  
  9. Start the engine and allow it to reach operating temperature. Check for leaks.
  10.  

3.0L (VIN T)
  1. Remove the air intake hose, as necessary.
  2.  
  3. Label and remove the spark plug wires.
  4.  
  5. Remove the breather and PCV hoses.
  6.  
  7. Remove the rocker cover.
  8.  

To Install:
  1. Clean all rocker cover gasket mating surfaces.
  2.  
  3. Inspect the breather and PCV ports, camshaft end seal and valve cover end seals. Repair or replace as necessary.
  4.  
  5. Apply a 0.4 in. (10 mm) bead of Three Bond No. 1212D or equivalent sealant to the top surface of the cylinder head and cam cap. Refer to illustration for specific application points.
  6.  
  7. Install the rocker cover and tighten bolts to 6-7 ft. lbs. (8-10 Nm).
  8.  

Do not overtighten the valve cover bolts, because warpage of the valve cover and oil leakage could result.

  1. Install the breather and PCV hoses.
  2.  
  3. Install the spark plug wires.
  4.  
  5. Install the air intake hose.
  6.  
  7. Start the engine and allow it to reach operating temperature. Check for leaks.
  8.  

Except 1.5L (VIN E), 1.5L (VIN J), 1.5L (VIN K) and 3.0L (VIN T) Engines



Click image to see an enlarged view

Fig. Fig. 9: Apply a 0.4 in. (10 mm) bead of Three Bond No. 1212Dor equivalent sealant to each end of the rocker coveras illustrated-except 1.5L (VIN E), 1.5L (VIN J) and 3.0L (VIN P) engines



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Fig. Fig. 10: Rocker cover bolts are of different lengths.Bolts marked as (*) are 25 mm long. Bolts markedas (**) are 20 mm long. Bolts marked as (***) are 15 mm long

  1. Remove the air intake hose, as necessary.
  2.  
  3. Remove the rocker arm center cover.
  4.  
  5. Label and remove the spark plug wires.
  6.  
  7. Remove the breather and PCV hoses.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Remove the rocker cover.
  12.  

To Install:
  1. Clean all rocker cover gasket mating surfaces.
  2.  
  3. Inspect the breather and PCV ports, camshaft end seal and valve cover end seals. Repair or replace as necessary.
  4.  
  5. Apply a 0.4 in. (10 mm) bead of Three Bond No. 1212D or equivalent sealant to the top surface of the cylinder head and cam cap. Refer to illustration for specific application points.
  6.  
  7. Install the rocker cover and tighten bolts to 2-3 ft. lbs. (3-4 Nm) on 2.0L (VIN P) and 6-7 ft. lbs. (8-10 Nm) on all other engines.
  8.  

Do not overtighten the valve cover bolts, because warpage of the valve cover and oil leakage could result.

  1. Install the upper timing belt cover and tighten bolts to 7-8 ft. lbs. (10-12 Nm).
  2.  
  3. Install the breather and PCV hoses.
  4.  
  5. Install the spark plug wires.
  6.  
  7. Install the air intake hose.
  8.  
  9. Install the rocker arm center cover and tighten bolts to 6-7 ft. lbs. (8-10 Nm).
  10.  
  11. Start the engine and allow it to reach operating temperature. Check for leaks.
  12.  

Do not overtighten the valve cover bolts, because warpage of the valve cover and oil leakage could result.

  1. Run the engine until normal operating temperature is reached. Shut the engine off and check for oil leaks.
  2.  

 
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