This procedure covers the removal and replacement of all rocker arms on the 2.5L I4 engine, requiring removal of the valve cover and camshafts.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM specification
• Valve cover bolt grommets × 12 — Use OEM specification
• Rocker arms (as needed) × 16 — Use OEM specification
• Camshaft front seal (if damaged) × 1 — Use OEM specification
• Camshaft rear seal (if damaged) × 1 — Use OEM specification
• Engine oil × 1 — Hyundai Genuine 0W-20

Fluids

• Hyundai Genuine 0W-20 — 5 qt

Preparation

1. Ensure engine is completely cold
2. Disconnect negative battery cable and wait 3 minutes
3. Remove engine cover by pulling upward on front clips
4. Drain engine oil completely and replace drain plug
5. Remove air intake duct and air filter housing
6. Label and disconnect all electrical connectors from valve cover area (ignition coils, PCV, etc.)
7. Remove ignition coils and spark plugs
8. Disconnect PCV hoses and breather hoses from valve cover
9. Support engine with jack and remove right side engine mount if needed for access

Procedure

1. 1

   Remove valve cover
   Remove valve cover bolts in reverse of tightening sequence (starting from outside, working inward). Carefully lift valve cover off. If stuck, gently tap with plastic mallet. Do not pry between cover and head as this will damage sealing surfaces.
2. 2

   Rotate engine to TDC cylinder 1
   Rotate crankshaft clockwise using bolt at front of crankshaft until timing marks on camshaft sprockets align with marks on timing chain cover or cylinder head. Verify cylinder 1 is at TDC compression stroke (both cam lobes pointing away from rocker arms). Mark timing chain to sprocket relationship with paint marker.
   ⚠Only rotate engine by crankshaft bolt, never by camshaft. Rotation in wrong direction can damage variable valve timing system.
3. 3

   Lock timing chain tensioner
   Compress timing chain tensioner and insert locking pin (3mm diameter) through hole to lock tensioner in retracted position. This prevents timing chain from jumping or becoming misaligned during camshaft removal.
4. 4

   Remove camshaft sprocket bolts
   Hold camshafts in position using camshaft holding tool to prevent rotation. Remove intake and exhaust camshaft sprocket bolts. Leave sprockets loosely positioned on camshafts with timing chain engaged. Do not allow timing chain to drop into engine.
   ⚠Support timing chain with wire to prevent it from falling into timing cover. Chain falling can cause misalignment and require front cover removal.
5. 5

   Remove camshaft bearing caps
   Loosen camshaft bearing cap bolts evenly in sequence, working from outside to inside in multiple passes (1/4 turn each). Remove bearing caps and keep in order with identifying marks visible. Note that caps are numbered and directional. Remove camshaft sprockets and support timing chain with mechanic wire.
   ⚠Never loosen bearing caps unevenly or skip sequence. This can warp camshafts or crack bearing caps due to valve spring pressure.
6. 6

   Remove camshafts
   Carefully lift intake and exhaust camshafts straight up and out of cylinder head. Place on clean protected surface with lobes facing up. Inspect camshaft journals and lobes for scoring or wear.
7. 7

   Remove and inspect rocker arms
   Remove all 16 rocker arms from cylinder head. Keep each rocker arm with its corresponding hydraulic lash adjuster if reusing. Place in numbered magnetic tray or cardboard organizer in exact order of removal. Inspect rocker arm pad surfaces and roller for wear, scoring, or pitting. Inspect hydraulic lash adjusters for collapse or leakage. Replace any damaged components.
   ℹ️Rocker arms and lash adjusters wear together as matched sets. If reusing, they must return to exact original positions.
8. 8

   Clean and inspect cylinder head surface
   Clean all rocker arm bores and camshaft journals with brake cleaner and lint-free cloth. Inspect camshaft journal surfaces in cylinder head for scoring or damage. Check that all oil passages are clear. Clean valve cover mating surface on cylinder head using gasket scraper, being careful not to gouge aluminum.
9. 9

   Install rocker arms and lash adjusters
   Lubricate all hydraulic lash adjusters with clean engine oil. Install lash adjusters into cylinder head bores in original positions (or new positions if replacing all). Lubricate rocker arms with clean engine oil and install onto lash adjusters in correct positions. Ensure rocker arms move freely on lash adjusters.
10. 10

    Install camshafts
    Lubricate all camshaft journals and lobes liberally with clean engine oil. Carefully lower camshafts into position, ensuring intake and exhaust camshafts are in correct positions (check identification marks). Align camshafts so timing marks face upward and lobes are positioned away from rocker arms for cylinder 1.
11. 11

    Install camshaft bearing caps
    Install camshaft bearing caps in correct positions following numbers and directional arrows. Hand-tighten bolts, then torque in sequence from inside to outside in multiple passes. First pass to 5 Nm, second pass to 12 Nm, final pass to specification. Ensure camshafts rotate freely after installation.
    ⚠Bearing cap bolts must be tightened in correct sequence and gradually. Uneven tightening will warp camshafts and cause premature failure.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)
12. 12

    Install camshaft sprockets and timing chain
    Remove mechanic wire supporting timing chain. Install camshaft sprockets onto camshafts, aligning timing marks with marks made during disassembly. Hold camshafts with holding tool and install sprocket bolts. Verify all timing marks align correctly. Remove locking pin from timing chain tensioner.
    ⚠️Verify timing marks are perfectly aligned before removing tensioner pin. Incorrect timing will cause catastrophic engine damage on startup.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)
13. 13

    Verify valve timing and operation
    Manually rotate crankshaft two complete revolutions clockwise and verify timing marks realign at TDC cylinder 1. Check that all rocker arms operate smoothly without binding. Verify timing chain has proper tension after tensioner release.
14. 14

    Install valve cover
    Install new valve cover gasket and bolt grommets. Ensure gasket is properly seated in valve cover groove. Clean valve cover mating surface. Apply thin bead of RTV sealant to corners where timing chain cover meets cylinder head if specified. Place valve cover onto cylinder head and install bolts. Tighten bolts in sequence from center outward.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
15. 15

    Reinstall remaining components
    Install spark plugs and ignition coils. Reconnect all PCV and breather hoses. Reconnect all electrical connectors. Reinstall air filter housing and intake duct. Reinstall engine mount if removed. Reinstall engine cover. Reconnect battery negative cable.

Reassembly

1. Refill engine with correct quantity and specification of engine oil (5.0 quarts Hyundai Genuine 0W-20)
2. Do not start engine immediately - allow hydraulic lash adjusters to settle for 30 minutes
3. Prime oil system by cranking engine with fuel pump fuse removed for 10 seconds
4. Reinstall fuel pump fuse and start engine

Verification

• Start engine and verify no oil leaks from valve cover gasket or camshaft seals
• Listen for abnormal valve train noise - slight ticking for first 30 seconds is normal as lash adjusters pump up
• Verify no check engine light or timing-related fault codes
• Allow engine to reach operating temperature and verify smooth idle with no misfires
• Check oil level and top off if needed after running engine
• Road test vehicle and verify normal power and acceleration with no hesitation or timing chain noise

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