Hyundai Genesis: 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.

1.	Remove the LH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

2.	Remove the LH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

3.	Remove the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

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

5.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

6.

Remove the LH cylinder heads assembly. (1) When removing the cylinder head bolts, do not completely loosen the bolts at a time. Loosen them in two or three steps according to the sequence shown below. Head warpage or cracking could result from removing bolts in an incorrect order. (2) Lift the 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 cylinder head gasket.

1.	Remove the RH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

2.	Remove the RH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

3.	Remove the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

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

5.

Remove the RH cylinder head assembly. (1) Remove the RH cylinder head rear bolt (A). [3.8L] (2) When removing the cylinder head bolts, do not completely loosen the bolts at a time. Loosen them in two or three steps according to the sequence shown below. Head warpage or cracking could result from removing bolts in an incorrect order. (3) Lift the 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 cylinder head gaskets.

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 mechanical lash adjusters (MLA) (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 oil control valve (OCV) (A).

Inspection

1.

Inspect for flatness. Using a precision straight edge and feeler gauge, measure the flatness of the surface where the cylinder block contacts the manifold. Flatness of cylinder head gasket surface Standard : Less than 0.05 mm (0.002 in.) [Less than 0.02 mm (0.0008 in.) / 150x150] Flatness of manifold gasket surface Standard : Less than 0.01 mm (0.0004 in) [Less than 0.03 mm (0.001 in.) / 110x110]

2.	Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracks are found, replace the cylinder head.

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 ~ 5.512 mm (0.216 ~ 0.217 in.) (2) Using a micrometer, measure the diameter of the valve stem. Valve stem O.D. Intake : 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.) Exhaust : 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.) (3) To measure the valve stem-to-guide clearance, subtract the valve guide inside diameter from the valve stem diameter. Valve stem-to-guide clearance [Standard] Intake : 0.020 ~ 0.047 mm (0.0008 ~ 0.0018 in.) Exhaust : 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in.) [Limit] Intake : 0.07 mm (0.0027 in.) Exhaust : 0.09 mm (0.0035 in.)

2.

Inspect valves. (1) Check the valve face angle with the ground. (2) Check that the surface of the valve for wear. If the wear is excessive, 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 ~ 1.86 mm (0.06142 ~ 0.07323 in.) Exhaust : 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.) (4) Check the valve length. Length Intake : 105.27 mm (4.1445 in) Exhaust : 105.50 mm (4.1535 in) (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 (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 the 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.

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 : 46.2 mm (1.8189 in.) Out-of-square : MAX, 1.5°

1.	Inspect MLAs. Using a micrometer, measure the MLA outside diameter. MLA O.D. Intake/Exhaust : 34.964 ~ 34.980 mm (1.3765 ~ 1.3771 in.)

2.	Using a caliper gauge, measure MLA tappet bore inner diameter of the cylinder head. Tappet bore I.D. Intake/Exhaust : 35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)

3.	Subtract MLA outside diameter measurement from tappet bore inside diameter measurement. MLA to tappet bore clearance [Standard] Intake/Exhaust : 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.) [Limit] Intake/Exhaust : 0.07 mm (0.0027 in.)

Reassembly

• Thoroughly clean all parts to be assembled. • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. • Replace the valve stem 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 through the valve guides. • Assemble the valve stem seal so that it fully covers the surface of the head. (2) After applying engine oil to each end of the valves, install the valve, valve spring and spring retainer. When installing the valve spring, place the enamel-coated part to face the valve spring 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 mechanical lash adjusters (MLA). 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 intake camshaft oil control valve (OCV) (A). Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) • Install OCV with gray colored connector into RH bank. • Install OCV with black colored connector into LH bank. • In case of dropping the OCV, do not reuse it. • Keep the OCV clean. • Do not hold the OCV sleeve during servicing. • When installing the OCV in 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. • Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force. • The cylinder head gasket is a metal gasket. Take care not to bend it. • Rotate the crankshaft, set the No.1 piston at top dead center (TDC).

1.

Install the LH cylinder head. A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC. B. Apply sealant on cylinder block top face before assembling cylinder head gaskets. The assembly must be done within 5 minutes after the sealant is applied. Refer to the illustration below to apply the sealant. Bead width : 2.0 ~ 3.0 mm (0.078 ~ 0.118 in.) Sealant locations : 1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface Recommended sealant : Liquid sealant THREE BOND 1217H C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block. The assembly must be done within 5 minutes after the sealant is 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), When installing the cylinder head bolts, do not completely tighten the bolts at a time. Tighten them in two or three steps according to the sequence shown below. Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force. Tightening torque Head bolt: 37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°)

3.	Install the alternator. (Refer to Engine Electrical System - "Alternator")

4.	Install the fuel delivery pipe. (Refer to Engine Control / Fuel System - "Fuel Delivery System")

5.	Install the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

6.	Install the LH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

7.	Install the LH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

1.

Install the RH cylinder head. A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC. B. Apply TB 1217H sealant on cylinder block top face before assembling cylinder head gaskets. The assembly must be done within 5 minutes after the sealant is applied. Refer to the illustration below to apply the sealant. Bead width : 2.0 ~ 3.0 mm (0.078 ~ 0.118 in.) Sealant locations : 1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface Recommended sealant : Liquid sealant THREE BOND 1217H C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block. The assembly must be done within 5 minutes after the sealant is 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) When installing the cylinder head bolts and plate washers, tighten them in two or three steps according to the sequence shown below. Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force. Tightening torque Head bolt: 37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°) Bolt (A): 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft) [3.8L] Using SST (09221-4A000), When installing the cylinder head bolts and plate washers, tighten them in two or three steps according to the sequence shown below.

3.	Install the fuel delivery pipe. (Refer to Engine Control / Fuel System - "Fuel Delivery System")

4.	Install the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

5.	Install the RH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

6.	Install the RH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

Cylinder Head Components and Components Location

Components 1. RH intake camshaft OCV2. Camshaft thrust bearing cap 3. Camshaft bearing cap 4. RH exhaust camshaft5. RH intake camshaft6. RH exhaust camshaft CVVT assembly7. RH intake camshaft CVV ...

Cylinder Block

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