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Home >> Hyundai >> 2018 >> Kona Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 214 (Cylinder Head Assembly - 1.6L) >> Cylinder Head >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different car, the 2021 Hyundai Kona. However, it is still accessible from the selected car via links, so may be relevant.

Engine removal is not required for this procedure.

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature 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.
NOTE:
  • Mark all wiring and hoses to avoid misconnection.
  • Turn the crankshaft damper pulley so that the No. 1 piston is at top dead center (TDC).
  1. Disconnect the battery negative terminal.
  2. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  3. Remove the air duct and air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  4. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  5. Disconnect the ECM connector and then remove the battery tray.

    (Refer to Engine Electrical System - "ENGINE CONTROL MODULE (ECM) ")

  6. Remove the battery tray.

    (Refer to Engine Electrical System - "BATTERY ")

  7. Remove the Engine Room under cover.
  8. Loosen the drain plug and drain the coolant. Open the radiator cap to make rapid draining.

    (Refer to Cooling System - "COOLANT ")

  9. Remove the radiator upper hose (A).
    G12593172Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing radiator hoses, install as displayed in images.
      G12593173Courtesy of HYUNDAI MOTOR AMERICA
  10. Remove the radiator lower hose (A).
    G12593174Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing radiator hoses, install as displayed in images.
      G12593175Courtesy of HYUNDAI MOTOR AMERICA
  11. Disconnect the intercooler inlet hose and pipe.
    1. Disconnect the intercooler inlet hose (A).

      Tightening Torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

      G12593176Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The groove of hose must be in line with the protrusion of the pipe.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
    2. Disconnect the intercooler inlet hose (A) from the turbocharger and remove the intercooler inlet pipe (B).

      Tightening Torque 

      Clamp: 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

      Mounting bolt: 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

      G12593177Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The groove of hose must be in line with the protrusion of the pipe or turbocharger.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  12. Remove the intercooler outlet hose and pipe.
    1. Disconnect the intercooler outlet hose (A).
    2. Disconnect the boost pressure sensor (BPS) connector (B).
    3. Disconnect the RCV solenoid hose (C).
    4. Disconnect the RCV solenoid connector (D).

      Tightening Torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

      G12593178Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The marking of hose must be in line with the stopper of the throttle body.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  13. Disconnect the engine wiring connector and harness clamp and then remove the cylinder head protector and wiring from engine.
    G12593179Courtesy of HYUNDAI MOTOR AMERICA
    G12593180Courtesy of HYUNDAI MOTOR AMERICA
  14. Disconnect the brake booster vacuum hose (A).
    G12593181Courtesy of HYUNDAI MOTOR AMERICA
  15. Remove the heater hoses (A).
    G12593182Courtesy of HYUNDAI MOTOR AMERICA
  16. Remove the vacuum pipe assembly (A).
    G12593183Courtesy of HYUNDAI MOTOR AMERICA
  17. Remove the cylinder head cover.

    (Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")

  18. Remove the timing chain cover.

    (Refer to Timing System - "TIMING CHAIN COVER & OIL PUMP ASSEMBLY ")

  19. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  20. Remove the camshaft.

    (Refer to Cylinder Head Assembly - "CVVT & CAMSHAFT ")

  21. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  22. Remove the turbo manifold.

    (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

  23. Remove the delivery pipe assembly.

    (Refer to Fuel System - "DELIVERY PIPE ")

  24. Disconnect the bypass hose, and then remove the water temperature control assembly.

    (Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")

  25. Remove the Heater Pipe.

    (Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")

  26. Remove the intake OCV (Oil Control Valve).

    (Refer to Fuel System - "CVVT OIL CONTROL VALVE ")

  27. Remove the rear hanger (A).
    G12593184Courtesy of HYUNDAI MOTOR AMERICA
  28. Remove the cylinder head cover heat protector (A).
    G12593185Courtesy of HYUNDAI MOTOR AMERICA
  29. Remove the cylinder head bolts, then remove the cylinder head.
    1. Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence displayed in image.
      Fig 1: Cylinder Head Bolts Loosening Sequence
      G12593186Courtesy of HYUNDAI MOTOR AMERICA
      CAUTION:
      • Head warpage or cracking could result from removing bolts in an incorrect order.
    2. Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks.
      CAUTION:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
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