Valve Cover Gasket - Single

Replace the valve cover gasket on the 2.5L I4 engine to eliminate oil leaks from the cylinder head mating surface.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM Hyundai/Kia gasket
• Spark plug tube seals × 4 — Often included with valve cover gasket set

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 3 minutes
3. Remove engine cover by pulling upward on clips
4. Take photos of electrical connector routing for reference during reassembly

Procedure

1. 1

   Remove air intake components
   Disconnect the air intake tube from the throttle body. Remove the air filter housing by disconnecting the breather hoses and unbolting the mounting bracket. Set aside to provide access to the valve cover area.
2. 2

   Disconnect PCV and breather hoses
   Locate the PCV hose connection on the driver side of the valve cover and disconnect it by squeezing the quick-disconnect fitting. Disconnect the breather hose on the passenger side of the valve cover. Note routing for reinstallation.
3. 3

   Remove ignition coil connectors and coils
   Press the locking tab and disconnect the electrical connector from each of the four ignition coils. Remove the single bolt securing each coil, then pull the coils straight up out of the spark plug tubes. Label or arrange coils in order for reinstallation.
4. 4

   Remove spark plugs
   Using a 14mm spark plug socket with extension, carefully remove all four spark plugs. Apply anti-seize compound to the threads of each spark plug in preparation for reinstallation. Inspect plugs for wear and replace if necessary.
   ℹ️Keep spark plugs in order to diagnose cylinder-specific issues if present.
5. 5

   Disconnect wiring harness from valve cover
   Locate any wiring harness clips or brackets attached to the valve cover. Carefully unclip or unbolt the harness to allow it to be moved aside. On some models, the ground wire may be attached to a valve cover bolt.
6. 6

   Remove valve cover bolts
   Remove all valve cover bolts in a crisscross pattern starting from the outside and working inward. There are typically 12-14 bolts. Keep bolts organized as some may be different lengths. Note the location of any brackets or ground wires attached to specific bolts.
   Torque spec

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

   Remove valve cover
   Gently tap the valve cover with a rubber mallet to break the gasket seal. Lift the valve cover straight up, being careful not to damage the head surface. If the cover is stuck, tap around the perimeter—do not pry with metal tools. Inspect valve train components for abnormal wear while exposed.
   ⚠Do not allow debris to fall into the open cylinder head. Cover the opening with clean shop towels if leaving unattended.
8. 8

   Remove old spark plug tube seals
   Using needle-nose pliers, carefully extract the old rubber spark plug tube seals from each of the four tubes in the cylinder head. These seals prevent oil from leaking into the spark plug wells. Ensure no pieces remain in the tubes.
   Torque spec

   Spark Plug Tube Seals12 Nm (9 lb-ft)
9. 9

   Clean mating surfaces
   Using a plastic gasket scraper, carefully remove all old gasket material from both the valve cover and cylinder head mating surfaces. Clean thoroughly with brake cleaner and lint-free towels. Inspect both surfaces for warping or damage. The surfaces must be completely clean and dry for proper sealing.
   ⚠Do not use metal scrapers on aluminum surfaces as this can cause gouges that prevent proper sealing.
10. 10

    Install new spark plug tube seals
    Lubricate the new spark plug tube seals lightly with clean engine oil. Press each seal firmly into its tube in the cylinder head using your fingers or a suitable socket until fully seated. Verify each seal is sitting flush and even.
    Torque spec

    Spark Plug Tube Seals12 Nm (9 lb-ft)
11. 11

    Install new valve cover gasket
    Position the new gasket into the groove on the valve cover. Ensure the gasket is fully seated all the way around the perimeter with no twists or folds. Some gaskets have alignment tabs that must be properly positioned.
12. 12

    Install valve cover and torque bolts
    Carefully lower the valve cover onto the cylinder head, aligning all bolt holes. Install all bolts hand-tight, ensuring any brackets or ground wires are in their original positions. Torque bolts in the proper sequence (typically starting from center and working outward in a spiral pattern) to specification. Make multiple passes, tightening gradually to final torque.
    ⚠Over-tightening valve cover bolts can warp the cover and cause leaks. Use a torque wrench and follow the tightening sequence.
    Torque spec

    Valve Cover Bolts10 Nm (7 lb-ft)
13. 13

    Reinstall spark plugs
    Thread each spark plug by hand into its cylinder to prevent cross-threading. Ensure anti-seize compound was applied to threads. Torque spark plugs to specification using a torque wrench.
14. 14

    Reinstall ignition coils
    Apply a small amount of dielectric grease to the inside of each coil boot. Insert each ignition coil into its spark plug tube, ensuring it seats fully onto the spark plug. Install the mounting bolt for each coil and torque to specification. Reconnect all electrical connectors.
15. 15

    Reconnect hoses and accessories
    Reconnect the PCV hose and breather hose to the valve cover, ensuring all quick-disconnect fittings click securely. Reinstall the air intake system and filter housing. Reattach any wiring harness clips to the valve cover. Reconnect the negative battery terminal.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all hoses are properly connected with no kinks
3. Ensure no tools or parts were left in the engine bay
4. Reinstall engine cover by pressing down on clips until seated

Verification

• Start the engine and listen for any unusual noises or misfires
• Inspect the valve cover perimeter for any signs of oil leakage while engine is running
• Allow engine to reach operating temperature and recheck for leaks
• After the first drive cycle, recheck valve cover area for oil seepage and verify all connections remain secure

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