Hyundai i-30: Cylinder Head Assembly / Cylinder Head

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head

Repair procedures

Removal

1.	Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")

2.	Remove the air duct and air cleaner assembly. (Refer to Intake and Exhasut System - "Air Cleaner")

3.	Remove the battery. (Refer to Engine Electrical System - "Battery")

4.	Remove the engine control module (ECM). (Refer to Engine Control / Fuel System - "Engine Control Module (ECM)")

5.	Remove the battery tray. (Refer to Engine Electrical System - "Battery")

6.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

7.	Drain the coolant. (Refer to Cooling System - "Coolant")

8.	Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).

9.	Remove the cylinder head cover. (Refer to Cylinder Heae Assembly - "Cylinder Head Cover")

10.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

11.	Remove the intake manifold. (Refer to Intake and Exhaust System - "Intake Manifold")

12.	Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")

13.	Remove the ITM (Intergrated Thermal Management). (Refer to Cooling System - "ITM (Intergrated Thermal Management).")

14.	Remove the heater pipe. (Refer to Cooling System - "Water Temperature Control Assembly")

15.	Remove the MHSG (Refer to Engine Electrical System - 'Mild Hybrid Starter Generator(MHSG)")

16.	Remove the delivery pipe. (Refer to Engine Control/Fuel System -"Delivery Pipe")

17.	Remove the vacuum pump. (Refer to Brake System - "Vacuum Pump")

18.	Remove the CVVT & camshaft. (Refer to Cylinder Head Assembly - "CVVT & Camshaft")

19.	Remove the CVVD & camshaft. (Refer to Cylinder Head Assembly - "CVVD Assembly")

20.	Remove the camshaft position sensor (A).

21.	Remove the cam carrier (A).

22.

Remove the hydraulic lash adjuster (HLA) (A) and the swing arm (B).

•	The HLA and swing arm should be kept together as pairs during storage after removal and reinstallation.

23.	Remove the spark plugs. (Refer to Engine Electrical System - "Spark Plug")

24.

Remove the cylinder head.

(1)

Using bit socket (12PT), uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence as shown.

•	Head warpage or cracking could result from removing bolts in an incorrect order.

(2)	Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

(3)	Remove the cylinder head gasket (B).

Disassembly

•	Identify, valves and valve springs as they are removed so that each item can be reinstalled in its original position.

Remove the valves.

(1)

Using the SST (09222-3K000, 09222-3K100), press the valve spring and remove retainer lock (A).

•	Do not press valve retainer more than 9mm (0.35 in.)

(2)	Remove the spring retainer (B).

(3)	Remove the valve spring (C).

(4)	Remove the valve (E).

(5)	Using the pliers, remove the valve stem seal (D).

(6)

Remove the valve seat.

•	Do not reuse old valve stem seals.

Inspection

Cylinder Head

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 0.05 mm (0.0020 in)

Less than 0.02 mm (0.0008 in) / 100 x 100

Flatness of manifold gasket surface

Standard : Less than 0.1 mm (0.0039 in)

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

Inspect valve stems and valve guides.

(1)

Using a caliper gauge, measure the inside diameter of the valve guide.

Valve guide I.D.

Intake :45.8 - 46.2 mm (1.8031 - 1.8188 in.)

Exhaust : 45.8 - 46.2 mm (1.8031 - 1.8188 in.)

(2)

Using a micrometer, measure the diameter of the valve stem.

Valve stem O.D.

Intake : 5.460 - 5.475 mm (0.2149 - 0.2155 in.)

Exhaust : 5.443 - 5.455 mm (0.2142 - 0.2247 in.)

(3)

Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to-guide clearance

Intake : 0.025 - 0.052 mm (0.00098 - 0.00204 in.)

Exhaust : 0.055 - 0.069 mm (0.00216 - 0.00271 in.)

Inspect valves.

(1)

Check the valve is ground to the correct valve face angle.

Valve face angle :

Intake/Exhaust : 45.25° - 45.75°

(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

Intake :0.85 - 1.15 mm (0.0334 - 0.0452 in.)

Exhaust : 1.15 - 1.45 mm (0.0452 - 0.0570 in.)

(4)

Check the valve length.

Length

Intake :45.8 - 46.2 mm (1.8031 - 1.8188 in.)

Exhaust : 45.8 - 46.2 mm (1.8031 - 1.8188 in.)

(5)	Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.

Inspect valve seats.

(1)	Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace cylinder head.

(2)	Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.

(3)

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.

Valve seat contact width

Intake : 0.85 - 1.15 mm ( 0.0334 - 0.0452 in)

Exhaust : 1.35 - 1.65 mm (0.0531 - 0.0649 in)

Valve seat angle :

Intake / Exhaust : 44.75° - 45.10°

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.

Intake Valve spring

Standard

Free height : 47.9 mm (1.8858 in)

Load :

16.7 ± 0.8 kgf.m / 35.5 mm (36.81 ± 1.76 lb / 1.3976 in.)

30.2 ± 1.4 kgf.m / 26.8 mm (65.57 ± 3.08 lb / 1.0905 in.)

Out of squareness : 1.5° MAX

Exhaust Valve spring

Standard

Free height : 54.3 mm (2.1377 in.)

Load :

23.5 ± 1.1 kgf.m / 35.5 mm (51.81 ± 2.42 lb / 1.3976 in.)

36.2 ± 1.2 kgf.m / 27.7 mm (79.81 ± 2.64 lb / 1.0905 in.)

Out of squareness : 1.5° MAX

HLA (Hydraulic Lash Adjuster)

With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.

Problem

Possible cause

Action

1. Temporary noise when starting a cold engine

Normal

This noise will disappear after the oil in the engine reaches the normal pressure.

2. Continuous noise when the engine is started after parking more than 48 hours

Oil leakage of the high pressure chamber on the HLA, allowing air to get in

Noise will disappear within 15 minutes when engine runs at 2000-3000 rpm.
If it doesn’t disappear, refer to step 7 below.

3. Continuous noise when the engine is first started after rebuilding cylinder head

Insufficient oil in cylinder head oil gallery

4. Continuous noise when the engine is started after excessively cranking the engine by the starter motor or band

•	Oil leakage of the high-pressure chamber in the HLA, allowing air to get in

•	Insufficient oil in the HLA

5. Continuous noise when the engine is running after changing the HLA

•	Do not run engine at a speed higher than 3000 rpm, as this may damage the HLA.

6. Continuous noise during idle after high engine speed

Engine oil level too high or too low

•	Check oil level.

•	Drain or add oil as necessary.

Excessive amount of air in the oil at high engine speed

Check oil supply system.

Deteriorated oil

Check oil quality.
If deteriorated, replace with specified type.

7. Noise continues for more than 15 minutes

Low oil pressure

Check oil pressure and oil supply system of each part of engine.

Faulty HLA

Remove the cylinder head cover and press HLA down by hand.
If it moves, replace the HLA.

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.

Install the valves.

(1)

Using the SST (09222-G2100, 09222-G2200), push in a new valve stem 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 seat.

(3)

Install the valve spring and spring retainer.

•	Place valve springs so that the cone shape side is upward retainer side.

(4)

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.

•	When installing the SST, insert the front support directly into the bolt hole on the cylinder head.

•	Do not press valve retainer more than 9 mm (0.35 in.).

(5)	Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.

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.

Install the cylinder head gasket.

(1)	The sealant locations on cylinder head gasket, cylinder block and cylinder head must be free of engine oil and etc.

(2)

Apply sealant MS721-40AA on the cylinder block top surface (Refer to below illustration) before assembling the cylinder head gasket.

Bead width : 2.0 - 3.0 mm (0.0787 - 0.1181 in)

(3)

Install the cylinder head gasket (B) on the cylinder block.

•	Be careful of the installation direction.

(4)

Apply sealant MS721-40AA on the cylinder head gasket top surface (Refer to below illustration) after assembling the cylinder head gasket.

Bead width : 2.0 - 3.0 mm (0.0787 - 0.1181 in)

(5)	Remove the extruded sealant after assembling the cylinder head assembly.

Install the cylinder head assembly.

(1)	Place the cylinder head assembly (A) quietly in order not to damage the gasket with the bottom part of the end.

(2)

Using SST (09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque :

12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 lb-ft) + 140 - 145° + 140 - 145°

•	Do not reuse the cylinder head bolts.

•	Do not apply engine oil on the bolt threads to achieve correct torque.

•	Remove the extruded sealant within 5 minutes after installing cylinder head bolts.

•	The engine running or pressure test should not be performed within 30minutes after installing cylinder head bolts.

•	Be careful not to change the installing position of the preassembled washer bolts and non-preassembled washer bolts.

•	When installing the washer of the non-preassembled washer bolts, the round and chamfer of washers should be faced up.

3.	Install the spark plugs. (Refer to Engine Electrical System - "Spark Plug")

Install the hydraulic lash adjuster (HLA) (A) and the swing arm (B).

(1)	When installing HLA, it should be held upright so that engine oil in HLA may not spill and assured that dust does not adhere to HLA.

(2)

HLA should be inserted carefully to the cylinder head not to spill engine oil.

If engine oil has spilled out of the lash adjuster, HLA bleeding should be performed according to the below procedure.

HLA bleeding procedure

Stroke the lash adjuster in engine oil by pushing its cap 4 to 5 times while pushing the ball down slightly using a hard steel wire. Be careful not to give the ball a hard push because the ball weighs just several grams.

If installing with engine oil spilling out of the lash adjuster and air in it, it might make an abnormal noise.

Place the cam carrier on the cylinder head.

(1)	Remove the hardening sealant, oil, cleaning residue, foreign materials gathered in the bottom of the cam carrier and on the top of the cylinder head.

(2)

Apply a continuous bead of liquid sealant to the bottom surface of the cam carrier, as shown in the illustration.

Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

Sealant : MS 721-40 AA or AA0

(3)

Install the cam carrier (A).

Tightening torque

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)

•	Tighten the cam carrier mounting bolts when installing the cam carrier.

Install the other parts reverse order of removal.

•	Refill engine with engine oil.

•	Refill a radiator and a reservoir tank with engine coolant.

•	Clean battery posts and cable terminals and assemble.

•

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 line.

•

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 engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system.

- Put the radiator cap on tightly, then run engine again and check for leaks.

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