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Repair Procedures: Installation

WARNING: This page is about a different car, the 2013 Hyundai Elantra GT. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Thoroughly clean all parts to be assembled.
  • Always use new cylinder head and manifold gaskets.
  • Always use new cylinder head bolts.
  • The cylinder head gasket is a metal gasket. Take care not to bend it.
  • Rotate the crankshaft to set the No. 1 piston at TDC (Top dead center) on compression stroke.
  1. Install the cylinder head gasket (B) on the cylinder block.
    1. Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the cylinder block and the cylinder head.
    2. Apply liquid gasket on the edge of the cylinder block.
    3. Install the cylinder head gasket with the dowel pins of the cylinder block.
    4. Apply liquid gasket on the edge of the cylinder head gasket.
      NOTE: Apply liquid gasket on the edge of the cylinder block and cylinder head gasket.

      Sealant:  Threebond 1217H (Hyundai Gray RTV) or equivalent

      Fig 1: Identifying Cylinder Head Gasket Edge Liquid Gasket Applying Area
      G09885513Courtesy of HYUNDAI MOTOR AMERICA
      CAUTION: Assemble the cylinder head gasket and the cylinder head within 5 minutes after applying sealant.
  2. Place the cylinder head (A) carefully to protect damage to the head gasket during installation.
    Fig 2: Identifying Cylinder Head, Gasket And Block
    G09885514Courtesy of HYUNDAI MOTOR AMERICA
  3. Install the cylinder head bolts with washers.

    Using SST (09221-4A000), install and tighten the 10 cylinder head bolts, in several passes, in the sequence as illustrated.

    Tightening torque 

    1st step:

    32.4 ~ 36.3 N.m (3.3 ~ 3.7 kgf.m, 23.9 ~ 26.8 lb-ft)

    2nd step: 90~95°

    3rd step: 90~95°

    Fig 3: Identifying Cylinder Head Bolts
    G09885515Courtesy of HYUNDAI MOTOR AMERICA
    Fig 4: Cylinder Head Bolts Tightening Sequence
    G09885516Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION:
    • Do not reuse the cylinder head bolts.
    • Do not apply engine oil on the bolt threads to achieve correct torque.
    • Remove the extruded sealant within 5 minutes after installing cylinder head bolts.
    • The engine running or pressure test should not be performed within 30 minutes after installing cylinder head bolts.
    • Be careful not to change the installing position of the preassembled washer bolts and non-preassembled washer bolts.
    • When installing the washer of the non-preassembled washer bolts, the round and chamfer of washers should be faced up.
    Fig 5: Identifying Cylinder Head Washers Chamfer
    G09885517Courtesy of HYUNDAI MOTOR AMERICA
  4. Install the rear engine hanger (A).

    Tightening torque: 

    34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)

    Fig 6: Identifying Rear Engine Hanger
    G09885518Courtesy of HYUNDAI MOTOR AMERICA
  5. Install the exhaust oil control valve (OCV) (A).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 7: Identifying Exhaust Oil Control Valve
    G09885519Courtesy of HYUNDAI MOTOR AMERICA
  6. Install the intake oil control valve (OCV) (A).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 8: Identifying Intake Oil Control Valve
    G09885520Courtesy of HYUNDAI MOTOR AMERICA
    CAUTION:
    • Do not reuse the OCV when dropped.
    • Keep the OCV filter clean.
    • Do not hold the OCV sleeve (A) during servicing.
    • When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
    Fig 9: Identifying OCV Sleeve
    G09885521Courtesy of HYUNDAI MOTOR AMERICA
  7. Install the oil control adapter (A) with a new gasket (B).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 10: Identifying Oil Control Adapter And Gasket
    G09885522Courtesy of HYUNDAI MOTOR AMERICA
  8. Install the water temperature control assembly.

    (Refer to "WATER TEMPERATURE CONTROL ASSEMBLY ")

  9. Install the hydraulic lash adjuster (HLA) (A) and the swing arm (B).
    Fig 11: Identifying Hydraulic Lash Adjuster And Swing Arm
    G09885523Courtesy of HYUNDAI MOTOR AMERICA
    1. When installing HLA, it should be held upright so that engine oil in HLA may not spill and assured that dust does not adhere to HLA.
    2. HLA should be inserted carefully to the cylinder head not to spill engine oil.
      CAUTION: In case of spilling, air bleed should be done in accordance with the air bleed procedure. Stroke HLA in diesel oil 4 ~ 5 times by pushing its cap while pushing the ball down slightly with a hard steel wire. (Take care not to severely push a hard steel wire down since ball is several grams.)
      Fig 12: Installing Hydraulic Lash Adjuster
      G09885524Courtesy of HYUNDAI MOTOR AMERICA
  10. Install the cam carrier.
    1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
    2. The sealant locations on the cam carrier and the cylinder head must be free of harmful foreign materials, oil, dust and moisture. Spray cleaner on the surface and wipe with a clean duster.
    3. After applying liquid sealant on the bottom surface of the cam carrier, assemble the cam carrier. Continuous bead of sealant should be applied to prevent any path from oil leakage.

      Bead width:  2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)

      Sealant:  Threebond 1217H or equivalent

      Fig 13: Identifying Cam Carrier Gasket
      G09885525Courtesy of HYUNDAI MOTOR AMERICA
    4. Place the cam carrier (A) on the cylinder head. The dowel pins on the cam carrier and holes on the cylinder head should be used as a reference in order to assemble the cam carrier in exact position.
    5. Fasten the cam carrier bolts.

      Tightening torque: 

      18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

      Fig 14: Identifying Cam Carrier
      G09885526Courtesy of HYUNDAI MOTOR AMERICA
      CAUTION:
      • Assemble the cam carrier within 5 minutes after applying sealant.
      • Assemble the camshaft bearing cap within 5 minutes after assembling the cam carrier.
      • The engine running or pressure test should not be performed within 30 minutes after assembling the cam carrier.
  11. Install the camshafts.
    1. Place the intake and exhaust camshafts (A) on the cam carrier.
      Fig 15: Identifying Intake/Exhaust Camshafts
      G09885527Courtesy of HYUNDAI MOTOR AMERICA
    2. Install the camshaft bearing cap (A).
      Fig 16: Identifying Camshaft Bearing Cap
      G09885528Courtesy of HYUNDAI MOTOR AMERICA

      Tighten the bolts, in several passes, in the sequence as illustrated.

      Tightening torque 

      M6 bolts:

      11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)

      M8 bolts:

      18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

      Fig 17: Camshaft Bearing Cap Bolts Tightening
      G09885529Courtesy of HYUNDAI MOTOR AMERICA
      CAUTION: Be careful not to change the position and direction of bearing caps.
  12. Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).

    Tightening torque: 

    64.7 ~ 76.5 N.m (6.6 ~ 7.8 kgf.m, 47.7 ~ 56.4 lb-ft)

    Fig 18: Identifying Intake/Exhaust CVVT Assembly
    G09885530Courtesy of HYUNDAI MOTOR AMERICA
    NOTE: When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.
    Fig 19: Removing CVVT Assembly Bolt
    G09885531Courtesy of HYUNDAI MOTOR AMERICA
  13. Install the PCSV bracket (A).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 20: Identifying PCSV Bracket
    G09885532Courtesy of HYUNDAI MOTOR AMERICA
  14. Install the condenser (A).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 21: Identifying Condenser
    G09885533Courtesy of HYUNDAI MOTOR AMERICA
  15. Install the vacuum pipe (A).

    Tightening torque: 

    9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 22: Identifying Vacuum Pipe
    G09885534Courtesy of HYUNDAI MOTOR AMERICA
  16. Install the other parts reverse order of removal.
  17. Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
    NOTE:
    • Refill engine with engine oil.
    • Refill a radiator and a reservoir tank with engine coolant.
    • Clean battery posts and cable terminals and assemble.
    • Inspect for fuel leakage.
      • After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
      • Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
    • Bleed air from the cooling system.
      • Start engine and let it run until it warms up (until the radiator fan operates 3 or 4 times).
      • Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
      • Put radiator cap on tightly, then run the engine again and check for leaks.
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