Complete removal and replacement of both cylinder head gaskets on the 2.5L I4 engine, including timing chain, camshafts, and cylinder head assembly.

Warnings

Tools required

Parts

• Cylinder head gasket set (includes both head gaskets) × 1 — Use OEM specification
• Cylinder head bolts (TTY, replace) × 20 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain tensioner gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Camshaft seal (intake and exhaust) × 4 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• RTV silicone sealant (timing cover) × 1 — Hyundai approved RTV

Fluids

• Hyundai Genuine 0W-20 — 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 to discharge
3. Remove engine cover and air intake system completely
4. Drain engine coolant into appropriate container by opening radiator drain and removing lower radiator hose
5. Drain engine oil and remove oil filter
6. Remove front bumper cover for access to cooling system components
7. Remove upper and lower radiator hoses, heater hoses, and coolant reservoir
8. Remove drive belts (serpentine and A/C if equipped)
9. Support engine with hoist or support fixture from above - transmission will remain in vehicle
10. Remove engine mount(s) as necessary for access to timing cover
11. Label and photograph all vacuum lines, electrical connectors, and hose routing before removal

Procedure

1. 1

   Remove intake and exhaust manifolds
   Disconnect throttle body, fuel rail, and all intake runners. Remove intake manifold bolts and lift manifold away. Disconnect oxygen sensors and remove exhaust manifold nuts from both cylinder banks. Remove exhaust manifolds and set aside with old gaskets removed.
   Torque spec

   Intake Manifold Bolts24 Nm (18 lb-ft)

   Exhaust Manifold Nuts34 Nm (25 lb-ft)
2. 2

   Remove valve covers
   Disconnect ignition coils and remove them from spark plug wells. Disconnect PCV hoses and any breather tubes. Remove valve cover bolts in reverse of tightening sequence (outward from center). Carefully lift valve covers and remove old gaskets. Inspect spark plugs and replace if necessary.
   Torque spec

   Valve Cover Bolts10 Nm (7 lb-ft)
3. 3

   Remove crankshaft pulley and timing cover
   Remove crankshaft pulley center bolt using impact wrench or by locking flywheel. Remove pulley from crankshaft. Remove timing cover bolts in reverse sequence and carefully pry cover away from engine block. Clean all RTV residue from mating surfaces.
   ⚠Crankshaft pulley bolt is high torque and may require impact wrench for removal. Do not use excessive force on crankshaft.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Timing Cover Bolts - 8mm25 Nm (18 lb-ft)
4. 4

   Mark and secure timing chain position
   Rotate crankshaft to TDC on cylinder #1 (both camshaft lobes on #1 cylinder pointing outward, timing marks aligned). Mark timing chain position relative to camshaft sprockets with paint pen. Mark crankshaft sprocket position. Install timing chain wedge tools if available to prevent chain from dropping into engine.
   ⚠️Proper timing mark documentation is critical. Take multiple photos from different angles. Incorrect timing will cause catastrophic engine damage on startup.
5. 5

   Remove timing chain tensioner and guides
   Remove timing chain tensioner bolt and carefully extract tensioner assembly. Note position of tensioner pin or lock. Remove timing chain guide bolts and guides. Keep all components organized for inspection and reinstallation.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
6. 6

   Remove camshaft sprockets and timing chain
   Hold camshaft on hex portion with wrench to prevent rotation. Remove camshaft sprocket bolts from all four camshafts (intake and exhaust on both banks). Carefully lift timing chain and sprockets as an assembly. Do not allow chain to fall into engine cavity. Stuff clean shop towels into chain cavity to prevent debris entry.
   ⚠Support timing chain at all times during removal. If chain falls into engine, complete disassembly may be required for retrieval.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)
7. 7

   Remove camshaft caps and camshafts
   Loosen camshaft cap bolts gradually in reverse sequence (outward from center) in multiple passes to prevent camshaft bending. Remove caps and mark them for position (intake/exhaust, bank, cylinder number). Lift camshafts straight up and out. Inspect cam lobes and journals for wear or scoring.
   ⚠Camshaft cap bolts must be loosened gradually in multiple passes. Uneven loosening can warp camshafts or cylinder heads.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
8. 8

   Remove rocker arms and lash adjusters
   If equipped with rocker arms, remove rocker arm bolts and lift rocker arms. Remove hydraulic lash adjusters and keep them organized by cylinder position. Store lash adjusters upright in clean oil to prevent air entry. Inspect rocker arms and lash adjusters for wear.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
9. 9

   Remove cylinder head bolts and heads
   Loosen cylinder head bolts in reverse of tightening sequence (outward from center) in multiple stages. Remove all head bolts and keep separate for disposal (TTY bolts cannot be reused). Carefully break cylinder head seal using plastic pry bars at designated pry points. Lift cylinder heads straight up to avoid damage. Remove old head gaskets and dowel pins.
   ⚠Never pry between head and block surfaces. Use only designated pry points to avoid damaging sealing surfaces.
   Torque spec

   Cylinder Head Bolts88 Nm (65 lb-ft)
10. 10

    Clean and inspect all mating surfaces
    Use plastic gasket scraper to remove all old gasket material from cylinder head and engine block surfaces. Clean surfaces with brake cleaner and lint-free towels. Inspect cylinder head surfaces with straightedge and feeler gauge for warpage (maximum 0.002 inch). Check block surface similarly. Resurface heads if out of specification. Inspect cylinder bores for scoring or damage.
    ⚠Metal scrapers can damage sealing surfaces. Use only plastic tools on aluminum surfaces.
11. 11

    Install new head gaskets and cylinder heads
    Ensure block and head surfaces are completely clean and dry. Install new dowel pins if removed. Position new head gaskets on block with UP marking facing cylinder head (check gasket orientation carefully). Do not use any sealant on head gaskets. Carefully lower cylinder heads into position, ensuring gaskets do not shift. Install new cylinder head bolts finger-tight in sequence.
    ⚠️Head gasket orientation is critical. Installing gaskets upside down or backwards will cause immediate failure and potential engine damage.
12. 12

    Torque cylinder head bolts
    Torque cylinder head bolts in proper sequence: First pass to 29 Nm (21 lb-ft) in sequence, second pass to 59 Nm (44 lb-ft) in sequence, third pass to final torque of 88 Nm (65 lb-ft) in sequence. Then apply additional angle torque: rotate each bolt an additional 90 degrees in sequence, followed by final 90 degrees in sequence (total 180 degrees angle after final torque). Verify all bolts have been angle-torqued properly.
    ⚠Angle torque must be applied in proper sequence after final torque value. Use angle gauge for accuracy - estimation will result in improper clamping force.
    Torque spec

    Cylinder Head Bolts88 Nm (65 lb-ft)
13. 13

    Install rocker arms, camshafts, and caps
    If equipped, lubricate and install hydraulic lash adjusters in original positions. Install rocker arms and torque bolts to specification with cam lobe pointing away from rocker. Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in correct positions (intake/exhaust marked on cam). Install camshaft caps in original positions with arrows pointing toward front of engine. Torque cap bolts in sequence from center outward in multiple passes to final specification.
    ⚠Camshafts must be installed in correct positions (intake vs exhaust). Mixing camshafts will prevent engine from running properly.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
14. 14

    Install timing chain, sprockets, and set timing
    Remove shop towels from timing chain cavity. Verify crankshaft is still at TDC for cylinder #1. Install timing chain and camshaft sprockets as assembly, aligning timing marks exactly as documented during disassembly. Install camshaft sprocket bolts finger-tight. Verify all timing marks are aligned correctly before proceeding. Hold camshafts on hex and torque sprocket bolts to specification. Install timing chain guides and tensioner (compress tensioner and install retaining pin before installation). Remove tensioner pin to apply tension. Rotate engine two complete revolutions by hand and verify timing marks realign at TDC.
    ⚠️Verify timing marks alignment multiple times before proceeding. Incorrect timing will cause piston-to-valve contact and destroy engine on startup.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
15. 15

    Install timing cover, crankshaft pulley, and remaining components
    Apply thin bead of Hyundai-approved RTV sealant to timing cover mating surface. Install new crankshaft front seal in timing cover. Install timing cover and torque bolts in proper sequence. Install crankshaft pulley and torque center bolt to specification (may require impact wrench). Install new valve cover gaskets and torque valve cover bolts in sequence from center outward. Install intake manifold with new gaskets and torque bolts in sequence. Install exhaust manifolds with new gaskets and torque nuts to specification. Reinstall all sensors, connectors, hoses, and accessories in reverse order of removal.
    Torque spec

    Timing Cover Bolts - 8mm25 Nm (18 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)

    Valve Cover Bolts10 Nm (7 lb-ft)

    Intake Manifold Bolts24 Nm (18 lb-ft)

    Exhaust Manifold Nuts34 Nm (25 lb-ft)

Reassembly

1. Reinstall engine mounts and remove engine support fixture
2. Reinstall cooling system components (radiator hoses, coolant reservoir)
3. Reinstall drive belts with proper tension
4. Reinstall air intake system and engine cover
5. Reinstall front bumper cover
6. Fill engine with specified 0W-20 oil (5 quarts) and new oil filter, torquing drain plug with new crush washer
7. Fill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level (approximately 10 quarts total capacity)
8. Reconnect battery negative cable

Verification

• Before starting engine, manually rotate crankshaft two complete revolutions to verify no interference and timing marks realign properly
• Check that all electrical connectors, vacuum lines, and hoses are reconnected
• Verify oil level on dipstick is at proper level
• Start engine and monitor for unusual noises, particularly valve train noise or timing chain rattle
• Allow engine to reach operating temperature and verify cooling fans operate normally
• Check for coolant, oil, or exhaust leaks around all gasket areas
• Monitor coolant level as system purges air - refill as necessary and burp cooling system completely
• Perform test drive and monitor engine temperature, oil pressure, and overall performance
• Recheck all fluid levels after test drive and verify no leaks
• Clear any diagnostic codes and verify no check engine light or warning messages
• Consider performing compression test to verify proper head gasket sealing if issues were present before repair

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