This procedure covers removal and replacement of the valve cover gasket on the 2.5L I4 engine in the 2016-2024 Hyundai Tucson AWD, including ignition coil removal and spark plug tube seal replacement.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM Hyundai part
• Spark plug tube seals × 4 — Use OEM Hyundai part
• Valve cover bolt grommets (if equipped) × 1 — Use OEM Hyundai part
• PCV valve grommet (inspect and replace if damaged) × 1 — Use OEM Hyundai part

Fluids

• Hyundai Genuine 0W-20 engine oil — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 2 hours)
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal using 10mm wrench
5. Remove engine cover by pulling upward on clips (if equipped)
6. Photograph ignition coil wire routing and connections for reference
7. Have a clean work area prepared for valve cover placement

Procedure

1. 1

   Remove air intake components
   Disconnect the air intake duct from the throttle body. Loosen the clamp at the air filter housing and remove the intake tube to provide access to the front of the valve cover. Set aside components in a clean area.
2. 2

   Disconnect ignition coil electrical connectors
   Press the locking tab on each ignition coil connector and pull straight up to disconnect. There are 4 ignition coils on this engine. Mark or photograph each connector position if they are not keyed differently.
3. 3

   Remove ignition coils
   Remove the single 10mm bolt from each ignition coil. Gently twist and pull each coil straight up out of the spark plug tube. Inspect the coil boots for damage or oil contamination. If oil is present in the tubes, this confirms the need for spark plug tube seal replacement.
   ⚠Do not pry on ignition coils. Use a gentle twisting motion to break the seal before pulling upward.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
4. 4

   Remove spark plugs
   Using a spark plug socket with extension, carefully remove all four spark plugs. Keep spark plugs in order if you plan to inspect them. Cover the spark plug holes with clean shop rags to prevent debris entry.
   ⚠️Never allow any debris, tools, or fasteners to fall into the open spark plug holes. Foreign objects will cause severe engine damage.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
5. 5

   Disconnect PCV hose and breather hoses
   Locate the PCV valve on the valve cover (typically rear driver side). Disconnect the PCV hose by squeezing the clip or pulling firmly. Disconnect any breather hoses attached to the valve cover. Note their positions for reinstallation.
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 11-13 bolts on this engine. Keep bolts organized and inspect the rubber grommets on each bolt - replace if damaged or compressed.
   ℹ️Valve cover bolts have rubber grommets that seal against oil seepage. These should be replaced if they show signs of cracking or permanent compression.
   Torque spec

   Cover Bolts16 Nm (12 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 and away from the cylinder head. Avoid prying against the sealing surface. Remove and discard the old gasket.
8. 8

   Remove old spark plug tube seals
   Using needle-nose pliers or a seal removal tool, carefully extract the old spark plug tube seals from the valve cover. These are press-fit rubber seals. Inspect the spark plug tube bores in the cylinder head for any debris or oil accumulation.
   ⚠Be careful not to scratch or damage the spark plug tube seal bores in the valve cover during removal.
9. 9

   Clean all mating surfaces
   Using a plastic gasket scraper, carefully remove all old gasket material from the valve cover and cylinder head mating surfaces. Clean both surfaces thoroughly with brake cleaner and lint-free rags. The surfaces must be completely clean and dry with no oil residue. Inspect for any damage, warping, or deep scratches.
   ⚠Do not use metal scrapers on the aluminum cylinder head surface as this can cause gouges that will prevent proper sealing. Use only plastic scrapers.
10. 10

    Install new spark plug tube seals
    Lightly oil the new spark plug tube seals with clean engine oil. Press the new seals into the valve cover by hand until they seat completely. The seals should be flush or slightly below the valve cover surface. A socket that matches the outer diameter can be used to press them in evenly.
    ℹ️Spark plug tube seals are press-fit only. Do not use adhesive or sealant on these seals.
    Torque spec

    Spark Plug Tube Seals0 Nm (0 lb-ft)
11. 11

    Install new valve cover gasket
    Position the new valve cover gasket in the groove on the valve cover. Ensure the gasket is fully seated in the channel all the way around and that any alignment features match correctly. Do not use any additional sealant unless specifically required by the gasket manufacturer.
12. 12

    Install valve cover
    Carefully lower the valve cover onto the cylinder head, ensuring proper alignment with all bolt holes and the spark plug tubes. Install all valve cover bolts with their grommets finger-tight first. Then torque the bolts in a crisscross sequence from the center outward to specification.
    ⚠Follow the proper tightening sequence starting from center bolts and working outward in a crisscross pattern. Over-tightening or improper sequence can warp the cover and cause leaks.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
13. 13

    Reinstall spark plugs
    Apply a small amount of anti-seize compound to the spark plug threads (avoid getting any on the electrode). Remove the protective rags from the spark plug holes. Carefully thread each spark plug by hand to avoid cross-threading, then torque to specification using a torque wrench.
    ⚠Always start spark plugs by hand to ensure proper threading. Cross-threading a spark plug in an aluminum head requires expensive thread repair.
    Torque spec

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
14. 14

    Reinstall ignition coils
    Apply a small amount of dielectric grease to the inside of each ignition coil boot. Press each coil firmly into its spark plug tube until it seats completely. Install and torque the 10mm mounting bolt on each coil. Reconnect all electrical connectors, ensuring they click into place.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
15. 15

    Reconnect hoses and reinstall components
    Reconnect the PCV hose and all breather hoses to their original positions. Reinstall the air intake tube and tighten the clamps securely. Reinstall the engine cover if equipped. Reconnect the negative battery terminal.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all hoses are properly connected and routed away from hot engine components
3. Double-check that no tools or rags were left in the engine bay
4. Confirm the air intake system is fully sealed with all clamps tight

Verification

• Start the engine and allow it to idle for 2-3 minutes while observing the valve cover area for any oil leaks
• Check for any unusual noises or rough running that might indicate an ignition coil not properly seated
• Rev the engine to 2500-3000 RPM briefly and recheck for leaks around the entire valve cover perimeter
• After the initial test, let the engine reach operating temperature and recheck for leaks
• After the first 50-100 miles of driving, inspect the valve cover area again for any signs of oil seepage
• Scan for any diagnostic trouble codes related to ignition system using an OBD-II scanner

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