Tucson 2006-2008

Cylinder Head

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Removal & Installation



2.0L Engine

Specific to:

Hyundai Tucson 2006-2008

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

    Negative battery cable
     
    Engine cover
     
    Air intake assembly
     
    Upper and lower radiator hose
     
    Heater hoses
     
    Engine wiring harnesses connectors and clamps from the cylinder head and intake manifold
     
    Fuel supply hose
     
    Purge Control Solenoid Valve (PCSV) hose
     
    Brake booster vacuum hose
     
    Throttle cable
     
    Power steering pump and mounting bracket
     
    Spark plug cables
     
    PCV hose
     
    Cylinder head cover
     
    Timing belt
     
    Exhaust manifold
     
    Intake manifold
     
    Camshaft sprocket
     
    Timing chain auto tensioner
     
    Camshaft bearing caps
     
    Camshafts
     
    Oil Control Valve (OCV)
     
    OCV filter
     
    Coolant hose from coolant pipe
     

  8.  
  9. Remove the cylinder head mounting bolts in sequence as shown.
  10.  
  11. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head removal sequence-2.0L engine

  12.  

To install:

  1. Install the cylinder head using a new gasket.
  2.  
  3. Apply a light coat of engine oil to the mounting bolts and tighten in sequence as shown:
    1. Step 1: M10 bolts to 18 ft. lbs. (25 Nm). M12 bolts to 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: Plus 60-65 degrees.
    4.  
    5. Step 3: Plus an additional 60-65 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-2.0L engine

    6.  

  4.  
  5. Install or connect the following:

    OCV filter and tighten to 30-38 ft. lbs. (41-51 Nm)
     
    OCV and tighten to 84-108 inch lbs. (10-12 Nm)
     
    Camshafts and bearing caps
     
    Timing chain auto tensioner
     
    Timing belt
     

  6.  
  7. Install the cylinder head cover and new gasket.
    1. Apply liquid gasket to the head cover gasket at the corners of the recesses.
    2.  
    3. Tighten the cylinder head cover mounting bolts uniformly in several passes to 72-89 inch lbs. (8-10 Nm).
    4.  

  8.  
  9. Install or connect the following:

    Intake manifold
     
    Exhaust manifold
     
    PCV
     
    Spark plug wires
     
    Power steering pump mounting bracket. Tighten to 26-37 ft. lbs. (35-50 Nm)
     
    Power steering pump
     
    Throttle cable
     
    Brake booster hose
     
    PCSV hose
     
    Fuel supply hose
     
    Engine wiring harnesses to the cylinder head and intake manifold
     
    Heater hoses
     
    Upper and lower radiator hoses
     
    Air intake assembly
     
    Engine cover
     
    Negative battery cable
     

  10.  
  11. Fill the engine with coolant to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  

2.7L Engine

Specific to:

Hyundai Tucson 2006-2008

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

    Negative battery cable
     
    Engine cover
     
    Air intake assembly
     
    Upper and lower radiator hoses
     
    Heater hoses
     
    Engine wiring harnesses from the cylinder head and intake manifold
     
    Fuel supply hoses
     
    Purge Control Solenoid Valve (PCSV) hose
     
    Brake booster vacuum hose
     
    Throttle cable
     
    PCV hose
     
    Intake manifold
     
    Power steering pump
     
    Exhaust manifold
     
    Timing belt
     
    Spark plug cable
     
    Cylinder head covers
     
    Camshaft bearing caps
     
    Camshafts
     
    Timing belt rear cover
     
    Water temperature control assembly and water pipe
     

  8.  
  9. Loosen the cylinder head bolts in several passes in the sequence shown.
    WARNING
    Head warping or cracking could result from removing bolts in an incorrect order.



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.7L engine

  10.  
  11. Remove the cylinder bolts and plate washer.
  12.  
  13. Remove the cylinder heads.
  14.  

To install:

  1. Install the cylinder heads with new gaskets.
  2.  
  3. Apply a light coat of engine oil the cylinder head bolts and tighten in sequence as follows:
    1. Step 1 = Tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2 = Plus 60 degrees.
    4.  
    5. Step 3 = Plus 45 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-2.7L engine

    6.  

  4.  
  5. Install or connect the following:

    Water pipe and water temperature control assembly. Tighten to 11-14 ft. lbs. (15-20 Nm)
     
    Timing belt rear cover. Tighten to 84-108 inch lbs. (10-12 Nm)
     
    Camshafts and camshaft bearing caps
     
    Cylinder head cover gaskets. Apply liquid gasket material to the gasket at the corners of the recess
     
    Cylinder head covers. Tighten bolts in sequence to 72-89 inch lbs. (8-10 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head cover bolt tightening sequence-2.7L engine

     

  6.  
  7. Install or connect the following:

    Spark plug cable
     
    Timing belt
     
    Exhaust manifold
     
    Power steering pump
     
    Intake manifold
     
    PCV hose
     
    Throttle cable
     
    Brake booster vacuum hose
     
    PCSV hose
     
    Fuel supply hose
     
    Engine wiring harnesses to the cylinder head and intake manifold
     
    Heater hoses
     
    Upper and lower radiator hoses
     
    Air intake assembly
     
    Engine cover
     
    Negative battery cable
     

  8.  
  9. Refill the engine with coolant to the correct level.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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