How to repair the cylinder head of Hyundai Elantra
Model: Hyundai Elantra(HD)
Year model: 2009
Fuel: Gasoline
Displacement:2009 G 1.6 DOHC Engine Mechanical System
Subject: How to repair the cylinder head of Hyundai Elantra(HD)
Study REMOVAL
Engine removal is not required for this procedure.
• Study Use Fender cover to avoid damaging painted surfaces.
• Study To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
• Study When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• StudyTo avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1.Study Disconnect the terminals(A) from battery and remove the battery.
2.Study Remove the engine cover(A).
3.StudyRemove the under cover(A).
4.Study Drain engine coolant.
Remove the radiator cap to speed draining.
5.Study Remove the air duct(A).
6.Study Remove the intake air hose(A) and air cleaner assembly.
(1)Study Disconnect the breather hose(B) from intake air hose(A).
(2)Study Disconnect the intake air hose(A) and accelerator cable(C).
(3)Study Disconnect the PCM connector(D).
(4)Study Remove the air cleaner assembly(E).
7.Study Remove the battery tray(A).
8.Study Remove the upper radiator hose(A) and lower radiator hose(B).
9.Study Loosen the water pump mounting bolt and the drive idler mounting bolt.
10.Study Loosen the alternator tension adjusting bolt(A) to loosen tension.
11.Study Remove the alternator drive belt(A).
12.Study Remove the alternator(A). (Refer to Alternator in EE Group).
13.Study Remove the RH front wheel.
14.Study Remove the engine mounting bracket(A) and the ground line(B).
Support the engine with a jack not to be tilted.
Do not support the engine - transaxle – sub frame assembly with the hangers.
15.Study Remove the alternator bracket.
16.Study Remove the engine support bracket(A).
17.Remove the water pump pulley(A)and Study.
18.Remove the water pump(A)and Study.
19.Remove the drive belt idler(A)and Study.
20.Disconnect the ignition coil connector(A) and the breather hose(B)and Study.
21.Disconnect the positive crankcase ventilation(PCV) hose(A), the engine cover bracket(B) and PCSV hose(C)Study.
22.Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold and Study.
(1)Disconnect the front(A) and the rear(B) oxygen sensor connector and Study.
(2)Disconnect the ignition coil condenser connector(C) and the purge control solenoid valve(PCSV) connector(D) and Study.
(3)Disconnect the throttle position sensor(TPS) connector(E) and Study.
(4)Disconnect the engine coolant temperature sensor(ECTS) connector(F) and the water hose(G) and Study.
23.Remove the ignition coil(A) and Study.
24.Remove the cylinder head cover bolts(A) and Study.
25.Remove the cylinder head cover(A) with its gasket(B) and Study.
26.Remove the side cover(A) and Study.
27.Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover and Study.
28.Remove the crankshaft bolt(B) and crankshaft pulley(A) and Study.
29.Remove the timing chain cover(A) and Study.
30.Study Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No.1 cylinder be positioned at TDC.
(1)Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
Put paint marks on the camshaft and the crankshaft sprockets aligning timing before removing the timing chain.
31.Remove the hydraulic tensioner (A) and Study.
32.Remove the timing chain tensioner arm(A) and guide(B) and Study.
33.Remove the timing chain(A) and Study.
34.Remove the camshaft bearing caps(A) with the order below and Study.
35.Remove the injector connectors(A) and the harness bracket(B)and Study.
36.Remove the delivery pipe(A) and Study.
37.Remove the exhaust manifold and Study.
38.Remove the intake manifold and Study.
39.Disconnect the camshaft position sensor(CMP) connector(A) and remove the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C) and Study.
40.Remove the water temperature control assembly and the oil control valve(OCV) and Study.
41.Remove the cylinder head bolts, then remove the cylinder head and Study.
(1)Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown and Study.
Head warpage or cracking could result from removing bolts in an incorrect order B and Study.
(2)Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks nad Study.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block and Study.
INSTALLATION
• Thoroughly clean all parts to be assembled and Study.
• Always use a new cylinder head and manifold gasket and Study.
• Always use a new cylinder head bolt and study.
• The cylinder head gasket is a metal gasket. Take care not to bend it and study.
• Rotate the crankshaft, set the No.1 piston at TDC and study.
1.Install the cylinder head assembly and study.
(1)Before installing, remove the hardened sealant from the cylinder block and cylinder head surface and study.
(2)Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes and study.
Refer to the illustration for applying sealant.
Width: 2.0 ~ 3.0mm(0.0787~0.1181in.)
Position: 1.0 ~ 1.5mm(0.0394~0.0591in.)
Specification: Three bond 1217H
(3)After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes and study.
2.Place the cylinder head carefully not to damage the gasket and study.
3.Install the cylinder head bolts with washers and study.
(1)Tighten the 10 cylinder head bolts, in several passes, in the sequence shown and study.
Tightening torque :
1st step - 17.7~21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0~15.9 lb-ft)
2nd step - 90°~95°
3rd step - 100°~105°
This study reminds you Always use new cylinder head bolts.
4.Install the oil control valve(OCV)(A) and study.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
5.Tighten the mounting bolts for the water temperature control assembly(A) after installing the heater pipe(B) and study.
Study the Tightening torque :
M6 bolts : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
M8 bolts : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
6.Connect the camshaft position sensor(CMP) connector(A) and install the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C) and study.
7.Install the intake manifold module assembly and study.
8.Install the exhaust manifold assembly and study.
9.Install the delivery pipe assembly(A) and study.
10.Install the injector connector(A) and harness bracket(B) and study.
11.Install the camshafts and study.
(1)Before installing, apply engine oil on journals and study.
Do not make oil flow down to the front side of the cylinder head.
(2)After installing, check the valve clearance and study.
12.Install the camshaft bearing caps with the order below and study.
Tightening torque :
M6 bolts - 11.8 ~ 13.7N.m (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lb-ft)
M8 bolts - 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
13.Align the timing marks of the camshaft sprocket with the upper sureface of the cylinder head to make No.1 cylinder be positioned at TDC and study.
(1)Check the dowel pin of the crankshaft for facing upside of the engine at this moment and study.
(2)Install the timing chain guide(A) and study.
14.After installation of the chain guide(A), reassemble the timing chain(B) and study.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
(1)When installing a timing chain, align the timing marks on the sprockets with ones of the chain and study.
Order : Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
15.Install the chain tensioner arm(A) and study.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
16.Fix the hydraulic tensioner(A) with a pin(B) before installing the tensioner(A) and remove the pin(B) after installing the tensioner(A) and study.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Recheck the top dead center(TDC) marks on the crankshaft and camshaft.
17.Install the timing chain cover(A) and study.
(1)Before installing, remove the hardened sealant from the cylinder block and ladder frame surface and study.
(2)Apply the sealant, THREE BOND 1282B on the timing chain cover and the water pump of the oil pump and the sealant, THREE BOND 1217H on the rest parts and study.
Width: 3.5 ~ 4.5mm (0.1378~0.1772in.)
(3)Apply the liquid gasket(1217H) on the surface between the cylinder head and the cylinder block and reassemble the cover(A) within five minutes and study.
Width: 3 ~ 5mm (0.1181~0.1969in.)
Remove oil or dust on the surface surely.
(4)Align the dowel pin of the cylinder block and the holes of the oil pumpand study.
Tightening torque :
12mm bolts - 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
10mm bolts - 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Study After the installation, do not crank engine or apply pressure on the cover for half an hour.
18.Using the SST(09455-21200), reassemble the timing chain oil seal(A)and study.
19.Install the crankshaft pulley(A) and study.
Tightening torque :
127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lb-ft)
When study installing the pulley, remove the starter and fix the SST(09231-2B100).
When study installing the pulley, the groove on the pulley should be positioned outside.
20.Install the side cover(A) and study.
Tightening torque :
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)
study
22.Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface and study.
23.After applying the liquid gasket, THREE BOND 1217H on the cylinder head cover, reassemble the cover within five minutes and study.
Width : 2.0 ~ 2.5mm(0.0787~0.0984in.)
24.Install the cylinder head cover(A) with a new gasket(B) and study.
Do not reuse the disassembled gasket of this study.
25.Tighten the cylinder head cover bolts(A) with the order and steps and study.
Tightening torque :
1st step - 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
2nd step - 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
26.Install the ignition coils(A) and study.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
27.Install the engine cover bracket(A), the positive crankcase ventilation(PCV) hose(B) and PCSV hose(C) and study.
28.Connect the ignition coil connector(A) and the breather hose(B) and study.
29.Install the drive belt idler(A) and study.
Study this Tightening torque :
42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
30.Install the water pump(A) with a gasket and study.
Study this Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
31.Install the water pump pulley(A) and study.
Study this Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Study Tighten the bolts diagonally.
32.Install the engine support bracket(A) and study.
Study Tightening torque :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
33.Install the alternator bracket(A) and study.
Study Tightening torque :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
34.Supporting the engine with a jack, install the engine mounting bracket(A) and the ground line(B) and study.
Study Tightening torque :
Bolt(C) - 58.8 ~ 83.4 N.m (6.0 ~ 8.5 kgf.m, 43.4 ~ 61.5 lb-ft)
Bolt, nut(D,E) - 49.0 ~ 58.8 N.m (5.0 ~ 6.0 kgf.m, 36.2 ~ 43.4 lb-ft)
Bolt(F) - 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
35.Install the alternator(A) and study.
Study Tightening torque :
12mm bolts - 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
10mm bolts - 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
36.Install the drive belt(A)and study.
37.Adjust tension by tightening the alternator tension adjust bolt(A).(Refer to Charging system in EE Group) study.
Study this Tension
New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)
Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
38.Connect the connectors on the cylinder head and install the clamps and study.
(1)Connect the front(A) and the rear(B) oxygen sensor connectorand study .
(2)Connect the ignition coil condenser connector(C) and the purge control solenoid valve(PCSV) conector(D) and study.
(3)Connect the throttle position sense (TPS) connector(E) andstudy.
(4)Connect the engine coolant temperature sensor (ECTS) connector(F) and the water hose(G) and study.
39.Install the fuel hose(A) and the accelerator cable(B) and study.
40.Connect the heater hose(A) and the brake booster hose(B) and study.
41.Connect the radiator upper hose(A) and lower hose(B) and study.
42.Install the battery tray(A) and study.
43.Install the air cleaner assembly and study.
Study Tightening torque :
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
(1)Connect the air cleaner hose(A) and bleeder hose(B) and Study.
(2)Install the accelerator cable(A) to the air cleaner assembly and Study.
(3)Connect the opwer control module (PCM) connectors(D) and Study.
44.Install the air duct(A) and Study.
Study Tightening torque :
7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
45.Install the under cover(A) and Study.
Study Tightening torque :
8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)
46.Install the engine cover(A) and Study.
Study Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Study Install the cover surely before driving.
47.Install the battery(B) and connect the terminals(A) and Study.
48.Refill engine coolant and engine oil and Study.
49.Start engine and check for leakage and Study.
50.Recheck the level of engine oil and coolant and Study.
STUDY DISASSEMBLY
Identify MLA(Mechanical lash adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.
1.Remove the MLAs(A) and Study.
When removing MLAs, mark all the MLAs for their rearrangement.
2.Remove the valves and .
(1)Using the SST (09222 - 3K000, 09222 - 3K100), compress the valve spring and remove the retainer lock.
(2)Remove the spring retainer.
(3)Remove the valve spring.
(4)Remove the valve.
(5)Remove the valve stem seal.
(6)Using a magnetic finger, remove the spring seat.
Do not reuse the valve stem seals.
INSPECTION
CYLINDER HEAD
1.Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm (0.0020in)
2.Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
VALVE AND VALVE SPRING
1.Inspect the valve stems and valve guides.
(1)Using a caliper gauge, measure the inner diameter of valve guide.
Valve guide inner diameter :
5.500 ~ 5.512mm (0.2165 ~ 0.2170in)
(2)Using a micrometer, measure the outer diameter of valve stem.
Valve stem outer diameter
Intake : 5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2154in)
(3)Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.
Valve stem- to-guide clearance
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0019in)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
If the clearance is greater than specification, replace the valve or the cylinder head.
2.Inspect the valves.
(1)Check the valve is ground to the correct valve face angle.
(2)Check that the surface of valve for wear.
If the valve face is worn, replace the valve.
(3)Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
Standard
Intake : 1.1mm (0.0433in)
Exhaust : 1.26mm (0.0496in)
(4)Check the length of valve.
Valve length
Standard
Intake : 93.15mm (3.6673 in)
Exhaust : 92.60mm (3.6457 in)
(5)Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3.Inspect the valve seats.
(1)Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.
(2)Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
4.Inspect the valve springs.
(1)Using a steel square, measure the out-of-square of valve spring.
(2)Using a vernier calipers, measure the free length of valve spring.
Valve spring
Standard
Free height : 44mm (1.7323in)
Out of square : Less than 1.5°
CAMSHAFT
1.Inspect the cam height.
Using a micrometer, measure the cam height.
Cam height
Intake : 43.85mm (1.7264in)
Exhaust : 42.85mm (1.6870in)
If the cam lobe height is less than specified, replace the camshaft.
2.Inspect the camshaft journal clearance.
(1)Clean the bearing caps and camshaft journals.
(2)Place the camshafts on the cylinder head.
(3)Lay a strip of plastigage across each of the camshaft journal.
(4)Install the bearing caps and tighten the bolts with specified torque.
Tightening torque :
M6 bolts : 11.8 ~ 13.7Nm (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lb-ft)
M8 bolts : 18.6 ~ 22.6Nm (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6lb-ft)
Do not turn the camshaft.
(5)Remove the bearing caps.
(6)Measure the plastigage at its widest point.
Bearing oil clearance
Standard : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in)
Limit : 0.1mm ( 0.0039in)
If the oil clearance is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
3.Inspect the camshaft end play.
(1)Install the camshafts.
(2)Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard : 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)
If the end play is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3)Remove the camshafts.
Continuous Variable Valve Timing(CVVT) ASSEMBLY
1.Inspect the Continuous variable valve timing(CVVT) assembly.
(1)Fix the Continuous variable valve timing(CVVT ) with its camshaft in a vice.
(2)Check that the CVVT assembly will not turn. If it is not turned, it is in normal condition.
(3)Apply vinyl tape to all the parts except the one hole.
(4)Using an air gun, apply the pressure, 147.10kpa (1.5kg/cm², 21.33psi) in the hole. This makes the lock pin in maximum retarded state released.
• Wrap around it with a shop rag and the likes, because the oil splashes.
• After releasing the pin, you can turn the CVVT assembly for advance by hand.
• If there may be much air leakage, the pin can not be released.
(5)Under the condition of 3), turn the CVVT assembly to the advance angle side with your hand.
A.Depending on the air pressure, the CVVT assembly will turn to the advance side.
B.Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
(6)Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no disturbance.
: Movable smoothly in the range about 25°
(7)Turn the CVVT assembly with your hand counterclockwise and lock it at the maximum delay angle position.
REASSEMBLY
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
• Replace oil seals with new ones.
1.Install the valves.
(1)Install the spring seats.
(2)Using the SST (09222 - 29000), push in a new oil seal.
Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.
Intake valve stem seals are different from exhaust ones in type. Do not reassembly ones in the other's places.
(3)Install the valve, valve spring and spring retainer, after applying engine oil at the end of each valve.
When installing valve springs, the enamel coated side should face the valve spring retainer.
2.Using the SST(09222 - 3K000, 09222 - 3K100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
When installing the SST, use the torque, 1.2kgf.m or less.
3.Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
4.Install the MLA(Mechanical lash adjuster) and Study.
Check that the MLA rotates smoothly by hand.
All the MLAs should be installed in its original position.
MORE CASE STUDY & PLEASE LEAVE US COMMENTS
