Complete valve job including cylinder head removal, valve grinding/replacement, seat machining, and reassembly with new seals and gaskets.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Hyundai/Kia specification
• Valve cover gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Valve stem seals (set) × 1 — Use OEM specification - 16 seals
• Cylinder head bolts (TTY) × 10 — Use OEM - replace all head bolts
• Camshaft cap bolts × 16 — Use OEM specification
• Engine oil and filter × 1 — 0W-20 specification
• Intake/exhaust valves (if replacement needed) × 1 — Use OEM - 8 intake, 8 exhaust
• Valve keepers/locks × 1 — Use OEM if damaged
• RTV silicone sealant × 1 — Hyundai genuine or equivalent high-temp
• Anti-seize compound × 1 — Copper-based high-temp

Fluids

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

Preparation

1. Ensure engine is completely cold - allow minimum 4 hours cooling time
2. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
3. Drain engine coolant completely into appropriate container by opening radiator drain and removing lower radiator hose
4. Drain engine oil and remove oil filter
5. Remove engine cover by pulling upward on clip locations
6. Remove air intake system including air filter housing and intake duct
7. Disconnect all electrical connectors from cylinder head area including injectors, ignition coils, camshaft sensors, and throttle body
8. Label and photograph all vacuum hoses and electrical connections for reinstallation reference
9. Support engine from below using jack and wood block under oil pan, or install engine support fixture across fender wells
10. Set up clean workspace with cylinder head stand and organize containers for hardware separation by location

Procedure

1. 1

   Remove valve cover and upper timing components
   Remove valve cover bolts in reverse of tightening sequence (outside to inside). Carefully lift valve cover and remove gasket. Remove upper timing chain cover bolts and separate cover. Inspect timing chain guides for wear. Take detailed photos of timing chain position on all sprockets.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
2. 2

   Set engine to TDC and lock timing
   Rotate crankshaft clockwise using bolt at front until cylinder #1 is at top dead center (TDC) on compression stroke. Verify timing marks on camshaft sprockets align with marks on timing chain or cylinder head. Install timing chain locking tools to prevent chain movement. Mark timing chain to sprockets with paint pen for reference.
   ⚠Never rotate engine counterclockwise as this can cause timing chain slack and jump timing
3. 3

   Remove camshaft sprockets and timing chain
   Hold camshaft on hex section with wrench to prevent rotation. Remove camshaft sprocket bolts from both intake and exhaust camshafts. Carefully remove sprockets while supporting timing chain with wire to prevent it from falling into timing cover. Remove timing chain tensioner bolt and extract tensioner. Remove timing chain guide bolts if accessible.
   Torque spec

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
4. 4

   Remove camshafts and rocker arms
   Loosen camshaft cap bolts gradually in reverse sequence (outward from center) in 2-3 passes to prevent camshaft distortion. Remove all cap bolts and carefully lift off camshaft caps, keeping them in order. Remove camshafts and mark intake/exhaust orientation. Remove rocker arms and hydraulic lash adjusters, keeping them organized by cylinder position for inspection and reinstallation in original locations.
   ⚠Camshaft caps are directional and position-specific - mark each cap clearly before removal
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)

   Rocker Arm Bolts30 Nm (22 lb-ft)
5. 5

   Disconnect manifolds and remove cylinder head
   Remove intake manifold bolts and separate intake manifold with gasket. Apply penetrating oil to exhaust manifold studs and allow to soak 15 minutes. Remove exhaust manifold nuts working from hot (center) to cold (outer) positions. Disconnect any remaining coolant hoses from cylinder head. Remove cylinder head bolts in reverse of tightening sequence in multiple passes. Carefully lift cylinder head straight up using proper lifting technique or hoist.
   ⚠Cylinder head weighs approximately 50-60 lbs - use proper lifting technique or assistance
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)

   Cylinder Head Bolts65 Nm (48 lb-ft)
6. 6

   Disassemble cylinder head valvetrain
   Mount cylinder head securely on head stand. Using valve spring compressor, compress each valve spring and remove valve keepers using magnetic tool. Carefully release spring tension and remove retainer, spring, and valve stem seal. Remove valve from combustion chamber side. Keep all valves in numbered order (cylinders 1-4, intake/exhaust). Inspect each valve for burning, pitting, or excessive wear on face and stem.
   ⚠️Valve spring compressor must be properly centered - valve keepers can become projectiles if spring releases suddenly
7. 7

   Inspect and measure valve components
   Measure valve stem diameter with micrometer - intake stem should be 5.47-5.48mm, exhaust 5.46-5.47mm. Measure valve margin thickness - minimum is 0.8mm for intake, 1.0mm for exhaust. Check valve face for pitting or burning requiring replacement. Measure valve spring free length and tension. Inspect valve guides for wear by measuring inside diameter - replace if beyond specification. Check cylinder head surface for warpage using precision straightedge and feeler gauge across multiple directions.
   ℹ️If head warpage exceeds 0.05mm or valves/seats are severely damaged, cylinder head requires professional machining
8. 8

   Machine valve seats and grind valves
   Using valve seat cutting tools or send to machine shop, cut intake valve seats to 45-degree angle with 1.0-1.2mm contact width centered on valve face. Cut exhaust seats similarly with 1.2-1.4mm contact width. Grind or lap each valve face to 45-degree angle ensuring smooth, even contact surface. After cutting, lap valves to seats using fine grinding compound in circular motion until even grey contact ring appears on both valve and seat. Clean all grinding compound thoroughly with solvent.
   ℹ️Valve-to-seat contact area must be centered on valve face - too high or low will cause premature failure
9. 9

   Test valve sealing and install new seals
   Test each valve seat by installing valve without spring, pouring solvent into port, and checking for leakage past seat. Properly sealed valve should hold solvent for 60+ seconds. Install new valve stem seals on each valve guide using seal driver tool, ensuring seal bottoms properly on guide. Lubricate valve stems with clean engine oil before installation.
   ⚠Do not tap valve stem seals directly on valve stem as this damages the seal - use proper seal installation tool on guide
10. 10

    Reassemble cylinder head valvetrain
    Install each valve into its original position from combustion chamber side, coating stem with clean oil. Install valve spring and retainer. Compress spring with compressor tool and carefully install valve keepers in stem groove. Slowly release compression and verify keepers are properly seated by tapping valve stem lightly with plastic mallet - should not move. Repeat for all 16 valves. Double-check all keepers are fully seated.
    ⚠Verify valve keepers are fully seated in stem grooves - improperly seated keepers will release under engine operation causing catastrophic damage
11. 11

    Prepare and install cylinder head
    Thoroughly clean cylinder head mating surface and engine block deck surface with solvent and plastic scraper - no gasket material or oil residue can remain. Verify block surface is clean and dry. Place new cylinder head gasket on block, aligning all dowel pins and bolt holes. Carefully lower cylinder head onto block, aligning with dowel pins. Install new cylinder head bolts (TTY) finger-tight in sequence.
    ⚠️Never reuse TTY cylinder head bolts - always install new bolts to prevent head gasket failure
12. 12

    Torque cylinder head bolts
    Following manufacturer tightening sequence (center outward), torque all head bolts to 65 Nm (48 lb-ft) in progressive passes: first pass to 20 Nm, second pass to 45 Nm, final pass to 65 Nm. After reaching final torque, mark reference point on each bolt head and block. Using angle gauge, rotate each bolt an additional 90 degrees plus 90 degrees (total 180 degrees additional) in proper sequence. Verify all bolts have rotated evenly.
    ⚠Angle tightening must be performed smoothly in one continuous motion per step - stopping and restarting invalidates torque specification
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
13. 13

    Install camshafts and set timing
    Lubricate all camshaft journals and lobes with engine assembly lube. Install hydraulic lash adjusters in original positions after soaking in clean oil. Install rocker arms with cam lobes pointing away from rocker contact surface. Install intake and exhaust camshafts in correct positions with timing marks visible. Apply thin bead of RTV sealant to front camshaft cap contact areas. Install camshaft caps in correct positions and orientation.
    Torque spec

    Rocker Arm Bolts30 Nm (22 lb-ft)
14. 14

    Torque camshaft caps and install timing components
    Tighten camshaft cap bolts in sequence from center outward in multiple passes: first pass to 5 Nm, second to 10 Nm, final to 14 Nm. Verify camshafts rotate freely by hand. Install timing chain on crankshaft sprocket, ensuring marked links align. Route chain around camshaft sprockets aligning all timing marks exactly as marked during disassembly. Install and hold camshafts on hex with wrench, then torque sprocket bolts to specification. Compress timing chain tensioner, install retaining pin, then install tensioner and torque bolt. Remove retaining pin to apply tension. Rotate engine two complete revolutions and verify all timing marks realign perfectly.
    ⚠️Incorrect timing alignment will cause catastrophic engine damage - verify timing marks multiple times before proceeding
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

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

    Reinstall manifolds and complete assembly
    Install new exhaust manifold gasket and exhaust manifold, applying anti-seize to studs. Torque nuts from center outward to specification. Install new intake manifold gasket and intake manifold, torque bolts to specification. Clean timing cover and cylinder head mating surfaces. Apply RTV sealant to specified locations on timing cover. Install timing cover and torque 8mm bolts in sequence. Clean valve cover and head mating surfaces thoroughly. Install new valve cover gasket. Apply small bead of RTV to front camshaft cap joints. Install valve cover and torque bolts in sequence from center outward. Reconnect all electrical connectors, vacuum hoses, and coolant hoses per photos taken during disassembly.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall air intake system and engine cover
2. Fill cooling system with specified Hyundai/Kia Long Life Coolant to proper level, burp air from system
3. Install new oil filter and fill engine with 5 quarts of Hyundai Genuine 0W-20 oil
4. Reconnect battery negative terminal
5. Before starting, manually rotate engine two complete revolutions by hand using crankshaft bolt to verify no interference or binding
6. Prime fuel system by cycling ignition on-off three times without cranking

Verification

• Start engine and monitor for unusual noises, vibrations, or warning lights - stop immediately if heard
• Allow engine to idle until reaching normal operating temperature while checking for coolant, oil, or exhaust leaks
• Verify valve cover, timing cover, head gasket, intake manifold, and exhaust manifold show no signs of leakage
• Check engine oil level and top off if needed - monitor for oil consumption over next 500 miles
• Test drive vehicle through varied throttle conditions and verify smooth operation with no misfires or hesitation
• Recheck valve cover and all gasket areas for leaks after engine has cooled following test drive
• After 500 miles, recheck engine oil level and inspect for any developing leaks at gasket interfaces

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