Complete replacement of all valve springs on the 2.5L I4 engine, requiring removal of camshafts and valve train components to access valve spring assemblies.

Warnings

Tools required

Parts

• Valve springs (set of 16) × 1 — Use OEM specification
• Valve stem seals (set of 16) × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Camshaft cap bolts (if reuse not recommended) × 20 — Use OEM specification
• Spark plug tube seals × 4 — Use OEM specification
• Timing chain guide (inspect for wear) × 1 — Use OEM specification
• Engine oil × 5 — Hyundai Genuine 0W-20
• Oil filter × 1 — Use OEM specification
• Anti-seize compound × 1 — Nickel-based

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 1 qt

Preparation

1. Ensure engine is completely cold (minimum 3 hours after last operation)
2. Disconnect negative battery cable and wait 3 minutes for airbag system discharge
3. Remove engine cover by pulling upward on retaining clips
4. Drain engine oil completely and remove oil filter
5. Drain coolant from radiator drain plug into appropriate container
6. Remove air intake assembly from throttle body to air filter housing
7. Disconnect all electrical connectors from valve cover (ignition coils, sensors)
8. Label and photograph all wiring routing and connector positions
9. Remove ignition coils from spark plug tubes
10. Create organized workspace with labeled containers for bolts from each step

Procedure

1. 1

   Remove spark plugs and valve cover
   Remove all four spark plugs using spark plug socket. Remove valve cover bolts in reverse of tightening sequence (outside to center pattern). Carefully lift valve cover away, tapping gently with plastic mallet if stuck. Inspect gasket mating surfaces for damage.
   Torque spec

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

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

   Position engine to TDC cylinder 1
   Rotate crankshaft clockwise using 22mm socket on crankshaft pulley bolt until timing marks on camshaft sprockets align with cylinder head surface. Verify cylinder 1 is at TDC compression stroke (both cam lobes pointing outward). Install timing chain locking tool to prevent chain movement.
   ⚠Verify TDC position carefully. Incorrect positioning will cause timing errors during reassembly.
3. 3

   Remove camshaft position sensors and timing components
   Remove intake and exhaust camshaft position sensors. Remove timing chain tensioner by removing mounting bolts. Remove timing chain guide mounting bolts. Mark camshaft sprocket-to-chain relationship with paint marker before removal.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)

   Mounting Bolts47 Nm (35 lb-ft)
4. 4

   Remove camshaft sprocket bolts
   Using camshaft holding tool to prevent rotation, remove intake and exhaust camshaft sprocket bolts. Carefully slide sprockets forward, keeping timing chain engaged. Support timing chain with wire to prevent it from falling into chain case. Do not allow chain to slip off crankshaft sprocket.
   ⚠️If timing chain falls into timing case, complete disassembly of front cover will be required.
5. 5

   Remove camshaft caps and camshafts
   Loosen camshaft cap bolts in reverse sequence (outward from center) in multiple passes, no more than 1/4 turn per pass to prevent cam distortion. Remove all camshaft caps, keeping them organized and labeled by position. Carefully lift out intake camshaft, then exhaust camshaft. Inspect cam lobes and journals for wear or damage.
   ⚠Camshaft caps are not interchangeable. Each cap must return to its exact original position and orientation.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
6. 6

   Remove rocker arms and lash adjusters
   Remove all rocker arms from valve stems, keeping them in order by cylinder and position (intake/exhaust). Remove hydraulic lash adjusters from their bores using magnetic pickup tool. Place each lash adjuster in clean engine oil in labeled container corresponding to its cylinder position. Do not mix lash adjusters between positions.
   ℹ️Lash adjusters must be stored upright in oil to prevent air from entering hydraulic chamber.
7. 7

   Compress and remove first valve spring
   Starting with cylinder 1 intake valve, install overhead cam valve spring compressor tool on valve spring. Compress spring carefully until keeper grooves are accessible. Use magnetic tool to remove valve keepers (two pieces per valve). Slowly release spring compressor tension. Remove valve spring retainer, valve spring, and valve stem seal. Inspect valve stem for damage.
   ⚠️Ensure valve spring compressor is properly seated before applying pressure. Misalignment can cause tool to slip and spring to release violently.
   ⚠Keep valve keepers from each valve separated. Dropping keepers into engine will require complete disassembly to retrieve.
8. 8

   Remove remaining valve springs
   Repeat valve spring removal process for all remaining 15 valves (cylinder 1 exhaust, cylinder 2 intake/exhaust, cylinder 3 intake/exhaust, cylinder 4 intake/exhaust). Keep all springs, retainers, and keepers organized by cylinder and valve position. Inspect each valve spring for cracks, damage, or compression height issues. Measure free height of springs if wear is suspected (compare to new springs).
   ℹ️This is time-intensive work. Take breaks to maintain focus and prevent errors in component organization.
9. 9

   Inspect valves and guides
   With springs removed, inspect each valve stem for scoring, wear, or bending. Check valve stem-to-guide clearance by attempting to rock valve laterally (excessive movement indicates guide wear). Inspect valve faces and seats for pitting or burning. Clean valve stem area and guide bore thoroughly with shop solvent and compressed air.
   ⚠If valve guide wear is excessive or valve damage is found, this repair may require cylinder head removal and machine work.
10. 10

    Install new valve stem seals
    Starting with cylinder 1 intake, lubricate new valve stem seal with clean engine oil. Carefully slide seal down valve stem using appropriate seal installation tool or deep socket. Press seal squarely onto valve guide until fully seated. Do not cock seal during installation. Repeat for all 16 valves.
    ⚠Damaged or improperly seated valve stem seals will cause excessive oil consumption.
11. 11

    Install new valve springs and retainers
    Install new valve spring over valve stem (ensure spring orientation matches original if springs are directional). Install valve spring retainer. Using valve spring compressor, compress new spring until keeper groove is accessible. Install both valve keepers into groove using magnetic tool, ensuring they seat properly in groove. Slowly release compressor and verify keepers are locked in place. Tap retainer lightly with plastic tool to confirm keeper engagement. Repeat for all 16 valves.
    ⚠️Verify both keepers are fully seated before releasing spring compressor. Improperly installed keepers will allow valve to drop into cylinder causing catastrophic engine damage.
12. 12

    Reinstall lash adjusters and rocker arms
    Remove each hydraulic lash adjuster from its oil bath and immediately install into its original bore in cylinder head. Install each rocker arm onto its corresponding valve stem and lash adjuster, ensuring rocker arm is properly positioned. Verify all 16 rocker arms are correctly installed before proceeding.
    ℹ️Lash adjusters must be installed in their original positions to maintain proper wear patterns.
13. 13

    Reinstall camshafts and caps
    Lubricate all camshaft journals and lobes liberally with clean engine oil. Install exhaust camshaft first, then intake camshaft, ensuring timing marks face upward and align properly. Install camshaft caps in their exact original positions (check markings: I for intake, E for exhaust, and position numbers). Hand-start all camshaft cap bolts. Tighten camshaft cap bolts in sequence from center outward in multiple passes (3 passes recommended: 5 Nm, 10 Nm, final 14 Nm torque).
    ⚠Uneven or rapid tightening of camshaft caps can distort camshaft and cause bearing damage or seizure.
    Torque spec

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

    Reinstall camshaft sprockets and timing chain
    Verify timing chain is still engaged on crankshaft sprocket and properly supported. Align painted timing marks on sprockets with chain. Install intake and exhaust camshaft sprockets onto camshafts, ensuring dowel pins engage properly. Using camshaft holding tool, install and torque sprocket bolts to specification. Verify all timing marks align correctly. Remove timing chain locking tool.
    ⚠️Incorrect timing will cause valves to contact pistons, resulting in severe engine damage when started.
15. 15

    Install timing components and sensors
    Install timing chain guide and torque mounting bolts. Install timing chain tensioner and torque mounting bolts (tensioner will automatically tension chain upon installation). Rotate engine two complete revolutions by hand and verify timing marks realign at TDC. Install camshaft position sensors and torque sensor bolts.
    ⚠Engine must rotate smoothly without binding. Any resistance indicates incorrect assembly.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)
16. 16

    Reinstall valve cover and spark plugs
    Clean all gasket surfaces on cylinder head and valve cover thoroughly with plastic scraper and solvent. Install new valve cover gasket and spark plug tube seals. Position valve cover onto cylinder head. Install valve cover bolts and tighten in sequence (center outward pattern) to specification. Apply anti-seize compound to spark plug threads. Install spark plugs and torque to specification.
    ⚠Over-torquing spark plugs in aluminum heads can strip threads, requiring expensive thread repair.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
17. 17

    Complete reassembly and fluid refill
    Reinstall ignition coils into spark plug tubes. Reconnect all electrical connectors to valve cover components. Install air intake assembly. Install new oil filter and refill engine with 5 quarts of Hyundai Genuine 0W-20 oil. Refill cooling system with Hyundai/Kia Long Life Coolant (Green). Reconnect battery negative cable. Install engine cover.
    ℹ️Do not start engine yet. Proceed to verification steps first.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify no tools or parts remain in engine compartment
3. Ensure all fluid drain plugs are tight and oil filter is secure
4. Check that all bolts removed during procedure have been reinstalled

Verification

• With ignition off, turn engine over by hand at least two full revolutions to verify smooth rotation without binding
• Check that timing marks still align properly at TDC after manual rotation
• Start engine and listen for unusual valve train noise (ticking, knocking, or rattling may indicate keeper or rocker arm installation issues)
• Allow engine to idle for 5 minutes while monitoring for oil leaks at valve cover gasket
• Check for coolant leaks at any disturbed cooling system connections
• Verify engine oil pressure warning light extinguishes within 5 seconds of startup
• Monitor for check engine light or camshaft position sensor codes after startup
• After engine reaches operating temperature, check for valve cover oil leaks again
• Perform test drive and verify normal engine performance and smooth operation at all RPM ranges
• Re-check engine oil level after test drive and top off if necessary (lash adjusters may absorb some oil)
• Check coolant level after engine cools and top off if needed

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