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Hyundai Azera: Cylinder Head Repair procedures - Cylinder Head Assembly - Engine Mechanical System - Hyundai Azera 2011-2024 Service ManualHyundai Azera: Cylinder Head Repair procedures

Fifth generation HG (2011–2024) / Hyundai Azera 2011-2024 Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Repair procedures

Removal
   
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
•
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
   
•
Mark all wiring and hoses to avoid misconnection.
•
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
[RH]
1.
Remove the RH camshafts.
(Refer to Cylinder Head Assembly - "Camshaft")
2.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
3.
Remove the RH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
4.
Remove the RH cylinder head.
(1)
Remove the RH cylinder head rear bolt (A).

(2)
Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

   
Head warpage or cracking could result from removing bolts in an incorrect order.
(3)
Lift the RH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

   
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(4)
Remove the RH cylinder head gasket.

[LH]
1.
Remove the LH camshafts.
(Refer to Cylinder Head Assembly - "Camshaft")
2.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
3.
Remove the LH exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
4.
Remove the LH cylinder head.
(1)
Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

   
Head warpage or cracking could result from removing bolts in an incorrect order.
(2)
Lift the LH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

   
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
(3)
Remove the LH cylinder head gasket.

Disassembly
   
Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original position.
1.
Remove the MLAs (A).

2.
Remove the valves.
(1)
Using the SST(09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

(2)
Remove the spring retainer.
(3)
Remove the valve spring.
(4)
Remove the valve.
(5)
Using the SST(09222-29000), remove the valve stem seal.

   
Do not reuse old valve stem seals.
3.
Remove the LH/RH intake camshaft OCV (A).

Inspection
Cylinder Head
1.
Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in.)
[Less than 0.02mm(0.0008in.)/150x150]
Flatness of manifold gasket surface
Standard : Less than 0.03mm(0.001in)/110x110

2.
Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.
Valve And Valve Spring
1.
Inspect valve stems and valve guides.
(1)
Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)

(2)
Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

(3)
Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)
[Limit]
Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)
2.
Inspect valves.
(1)
Check the valve is ground to the correct valve face angle.
(2)
Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3)
Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.)

(4)
Check the valve length.
Length
Intake : 105.27mm (4.1445in)
Exhaust : 105.50mm (4.1535in)
(5)
Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3.
Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4.
Inspect valve springs.
(1)
Using a steel square, measure the out-of-square of the valve spring.
(2)
Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 45.5mm (1.7913in.)
Out-of-square : 1.5°

MLA
1.
Inspect MLAs.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust :
34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)
2.
Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust :
35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)
3.
Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)
Camshaft
1.
Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 46.6mm (1.835in.)
Exhaust : 45.8mm (1.8031in.)

If the cam lobe height is less than standard, replace the camshaft.
2.
Inspect the camshaft journal clearance.
(1)
Clean the bearing caps and camshaft journals.
(2)
Place the camshafts on the cylinder head.
(3)
Lay a strip of plastigage across each of the camshaft journals.

(4)
Install the bearing cap (A) and thrust bearing cap (B) with specified torque. (Refer to Cylinder head in this group)
Tightening torque :
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

   
Do not turn the camshaft.
(5)
Remove the bearing caps.
(6)
Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.027 ~ 0.057mm (0.0010 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7)
Completely remove the plastigage.
(8)
Remove the camshafts.
3.
Inspect the camshaft end play.
(1)
Install the camshafts.
(2)
Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step : 5.8N.m (0.6kgf.m, 4.31lb-ft)
2st step : 9.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

(3)
Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(4)
Remove the camshafts.
Reassembly
   
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1.
Install the valves.
(1)
Using the SST(09222-3C100), push in a new oil seal.
   
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2)
Install the valve, valve spring and spring retainer.
   
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer.
(3)
Using the SST(09222 - 3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.

(4)
Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
2.
Install the MLAs.
Check that the MLA rotates smoothly by hand.

   
MLA can be reinstalled in its original position.
However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the cylinder block.
Refer to General information in EM section for Valve Clearance checking and adjustment procedure.
3.
Install the LH/RH inteke camshaft CVVT OCV(A).
Tightening torque
9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

   
•
Install OCV with gray colored connector into RH bank.
•
Install OCV with black colored connector into LH bank.
   
•
Do not reuse the OCV when dropped.
•
Keep the OCV clean.
•
Do not hold the OCV sleeve during servicing.
•
When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.
Installation
   
•
Thoroughly clean all parts to be assembled.
•
Always use a new head and manifold gasket.
•
The cylinder head gasket is a metal gasket. Take care not to bend it.
•
Rotate the crankshaft, set the No.1 piston at TDC.
[RH]
1.
Install the cylinder RH head.
A.
The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B.
Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.

   
Refer to below illustration to apply the sealant.
Bead width :
2.0~3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0~1.5mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant : TB 1217H (Hyundai Gray RTV) Liquid sealant

C.
Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

   
Be careful of the installation direction.

D.
Install the RH cylinder head.
   
Remove the extruded sealant after assembling cylinder heads.

2.
Install the RH cylinder head bolts.
(1)
Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2)
Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
   
Always use a new cylinder head bolts.
Tightening torque
Head bolt: 37.3~41.2N.m (3.8~4.2kgf.m, 27.5~30.4lb-ft) + (118~122°) + (88~92°)
Bolt (A):18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

3.
Install the other parts reverse order of removal.
   
•
Refill engine oil.
•
Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
•
Inspect for fuel leakage.
-
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
-
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
•
Refill radiator and reservoir tank with engine coolant.
•
Bleed air from the cooling system.
-
Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
-
Turn Off the engine and let it cool down. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
-
Put radiator cap on tightly, then run the engine again and check for leaks.
[LH]
1.
Install the cylinder LH head.
A.
The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B.
Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.

   
Refer to below illustration to apply the sealant.
Bead width :
2.0~3.0 mm (0.078 ~ 0.118 in.)
Sealant locations :
1.0~1.5mm (0.039 ~ 0.059 in.) from block surface
Recommended sealant : TB 1217H (Hyundai Gray RTV) Liquid sealant

C.
Apply TB 1217H (Hyundai Gray RTV) sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

   
Be careful of the installation direction.

D.
Install the LH cylinder head.
   
Remove the extruded sealant after assembling cylinder heads.

2.
Install the LH cylinder head bolts.
(1)
Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2)
Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
   
Always use a new cylinder head bolts.
Tightening torque
Head bolt: 37.3~41.2N.m (3.8~4.2kgf.m, 27.5~30.4lb-ft) + (118~122°) + (88~92°)

3.
Install the other parts reverse order of removal.
   
•
Refill engine oil.
•
Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
•
Inspect for fuel leakage.
-
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
-
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
•
Refill radiator and reservoir tank with engine coolant.
•
Bleed air from the cooling system.
-
Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
-
Turn Off the engine and let it cool down. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
-
Put radiator cap on tightly, then run the engine again and check for leaks.
Cylinder Head Components and Components Location
Components 1. RH Cylinder head2. RH Cylinder head gasket3. LH Cylinder head4. LH Cylinder head gasket5. Cylinder block 1. Camshaft bearing cap 2. Camshaft thrust bearing cap 3. RH Exhaust ca ...

Cylinder Block
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