Complete cylinder head gasket replacement for 2016-2024 Hyundai Tucson 2.5L I4 AWD engine, including timing chain removal, head removal, surface preparation, and reassembly with new gasket and head bolts.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Hyundai part
• Cylinder head bolts (TTY) × 1 — Use OEM Hyundai head bolt set
• Valve cover gasket × 1 — Use OEM specification
• Timing chain guide (inspect and replace if worn) × 1 — Use OEM specification
• Timing chain tensioner gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Standard M14 copper washer
• Engine oil filter × 1 — Use OEM or equivalent
• Coolant (Hyundai/Kia Long Life Green) × 10 — Use OEM coolant only
• Anti-seize compound × 1 — High-temperature nickel-based

Fluids

• Hyundai Genuine 0W-20 Engine Oil — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt

Preparation

1. Ensure engine is completely cold and vehicle is on level ground with parking brake engaged
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Remove engine cover and upper engine plastic covers
4. Drain engine coolant completely into appropriate container by opening radiator drain and lower radiator hose
5. Drain engine oil and replace oil drain plug with new crush washer
6. Remove intake air duct and air filter housing assembly
7. Label and disconnect all electrical connectors, vacuum hoses, and fuel lines from cylinder head area
8. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
9. Support engine from above using engine support fixture or hoist with load leveler

Procedure

1. 1

   Remove accessory components
   Remove spark plugs and ignition coils (label positions for reassembly). Disconnect and remove throttle body, fuel rail with injectors (keep assembled), and all wiring harnesses attached to cylinder head. Remove PCV valve and breather hoses. Disconnect coolant hoses from thermostat housing and cylinder head.
2. 2

   Remove intake and exhaust manifolds
   Remove intake manifold mounting bolts and carefully lift manifold away (may need gentle prying). Remove exhaust manifold heat shield. Remove exhaust manifold nuts working from center outward to prevent warping. Inspect exhaust studs for damage and replace if necessary.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts25 Nm (18 lb-ft)
3. 3

   Remove valve cover and timing components
   Remove valve cover bolts in reverse of tightening sequence and carefully lift valve cover. Remove right engine mount bracket for access to timing cover. Remove timing chain cover bolts and carefully separate cover from engine block. Rotate crankshaft to TDC on cylinder #1 (timing marks aligned on camshaft sprockets and crankshaft).
   ⚠Mark timing chain position relative to camshaft and crankshaft sprockets with paint before removal.
4. 4

   Remove timing chain tensioner and guides
   Remove timing chain tensioner bolt and carefully extract tensioner assembly. Remove timing chain guide bolts and guides. Inspect guides for wear grooves - replace if depth exceeds 1mm. Keep all components organized for inspection and reassembly.
5. 5

   Remove camshaft sprockets and timing chain
   Hold each camshaft with wrench on the hexagonal section while removing camshaft sprocket bolts. Remove both intake and exhaust camshaft sprockets. Carefully lift timing chain off crankshaft sprocket. Do NOT rotate crankshaft or camshafts from this point forward.
   ⚠️Do not allow camshafts to rotate. Valves will contact pistons causing severe damage.
6. 6

   Remove camshafts
   Loosen camshaft bearing cap bolts gradually in reverse sequence (outward from center) in multiple passes to release valve spring tension evenly. Remove bearing caps, keeping them organized by position and orientation. Carefully lift camshafts from cylinder head, noting intake and exhaust positions.
7. 7

   Remove cylinder head bolts and head
   Loosen cylinder head bolts in reverse of tightening sequence (from ends toward center) in multiple passes. Remove all head bolts completely and store separately - these MUST NOT be reused. Carefully break cylinder head loose from block using plastic mallet taps or gentle prying at designated lift points. Lift cylinder head straight up avoiding any pivoting motion. Place on clean, padded surface with combustion chambers facing up.
   ⚠Head is heavy (approximately 40 lbs). Use proper lifting technique or get assistance.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
8. 8

   Inspect and prepare cylinder head surface
   Remove all old gasket material from cylinder head surface using plastic gasket scraper. Clean surface thoroughly with brake cleaner. Inspect head surface for warpage using straight edge and feeler gauge - check diagonally, lengthwise, and crosswise. Maximum allowable warpage is 0.05mm (0.002 in). If warpage exceeds specification, cylinder head must be resurfaced by machine shop or replaced.
   ⚠Do not use metal scrapers on aluminum cylinder head surface. Scratches will cause gasket leaks.
9. 9

   Prepare engine block surface
   Carefully remove all old gasket material from engine block deck surface using plastic scraper. Stuff clean rags into cylinder bores to prevent debris from entering. Clean block surface thoroughly with brake cleaner and compressed air. Remove rags from cylinders and wipe bores with clean, lint-free cloth. Inspect block deck for warpage (same specification as head: 0.05mm max). Check that dowel pins are present and in good condition.
10. 10

    Install new head gasket and cylinder head
    Verify all surfaces are completely clean and dry. Position new head gasket on engine block, aligning with dowel pins. Verify gasket orientation - 'TOP' or 'FRONT' markings must be visible and correctly oriented. Carefully lower cylinder head onto block, aligning with dowel pins. Do not slide head across gasket surface. Install new cylinder head bolts finger-tight in sequence (center outward).
    ⚠️Only use NEW cylinder head bolts. Old TTY bolts have permanently stretched and will fail.
11. 11

    Torque cylinder head bolts - Multi-step sequence
    Using cylinder head bolt sequence (front to rear, alternating side-to-side from center): Step 1 - Torque all bolts to 40 Nm (30 lb-ft). Step 2 - Torque all bolts to 80 Nm (59 lb-ft) in same sequence. Step 3 - Using angle gauge, rotate each bolt an additional 90 degrees in same sequence. Wait 10 minutes, then verify no bolts have loosened. Final torque after angle tightening should read approximately 88 Nm (65 lb-ft) if checked.
    ℹ️Angle tightening is critical. Mark bolt heads with paint pen to track 90-degree rotation accurately.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
12. 12

    Install camshafts and bearing caps
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in correct positions (intake and exhaust marked on camshaft ends). Ensure rocker arms are properly positioned on valve stems. Install bearing caps in correct positions and orientation (numbers and arrows stamped on caps). Tighten bearing cap bolts in sequence from center outward in 3 progressive passes to final torque of 14 Nm (10 lb-ft).
13. 13

    Install timing chain and components
    Verify crankshaft is still at TDC position. Install timing chain over crankshaft sprocket, then route up and over camshaft sprockets, aligning timing marks with chain colored links or marks made during disassembly. Hold camshaft with wrench on hex while installing sprocket bolts. Torque camshaft sprocket bolts to 80 Nm (59 lb-ft). Install timing chain guides with new bolts torqued to 12 Nm (9 lb-ft).
14. 14

    Install timing chain tensioner and verify timing
    Compress timing chain tensioner and lock with pin or clip per manufacturer specification. Install tensioner with new gasket and torque bolt to 25 Nm (18 lb-ft). Remove tensioner locking pin/clip to apply tension. Rotate crankshaft 2 complete revolutions clockwise and verify timing marks realign at TDC. Install timing chain cover with new gasket.
    ⚠️If timing marks do not align after 2 rotations, DO NOT start engine. Remove and reinstall timing chain correctly.
15. 15

    Reassemble remaining components
    Install valve cover with new gasket, torque bolts in sequence to 10 Nm (7 lb-ft). Install exhaust manifold with new gasket, apply anti-seize to studs, torque nuts to 30 Nm (22 lb-ft) working from center outward. Install intake manifold with new gasket, torque bolts in sequence to 25 Nm (18 lb-ft). Install thermostat housing with new gasket, torque bolts to 15 Nm (11 lb-ft). Reconnect all coolant hoses, electrical connectors, vacuum lines, and fuel lines. Install ignition coils and spark plugs. Reinstall engine mount bracket and accessory components.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

Reassembly

1. Reinstall air intake system and engine covers
2. Fill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level - approximately 10 quarts total capacity
3. Fill engine with Hyundai Genuine 0W-20 oil (5 quarts) and install new oil filter
4. Reinstall fuel pump fuse and reconnect negative battery cable
5. Bleed cooling system by running engine with heater on full, adding coolant as level drops, until thermostat opens and no air bubbles appear

Verification

• Start engine and listen for abnormal noises - should run smoothly without ticking, knocking, or rattling
• Check for coolant, oil, and fuel leaks around all disturbed components while engine is running
• Verify engine reaches normal operating temperature (thermostat opens) and cooling fans cycle properly
• Check for exhaust leaks at manifold gasket - repair if found
• After engine cools, recheck coolant and oil levels and top off as needed
• Test drive vehicle and monitor temperature gauge, oil pressure light, and check engine light
• After 50-100 miles, recheck all fluid levels and inspect for any new leaks
• Scan for diagnostic trouble codes - address any codes related to camshaft position, timing, or misfires immediately

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