Removal
1. Drain the coolant and disconnect the radiator inlet hose.
2. Disconnect the crankcase ventilation hose from the air filter and cylinder head cover.
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3. Disconnect the air intake pipe.
4. Disconnect the vacuum hose, fuel hose and coolant supply hose.
5. Remove the high-voltage wire tips from the spark plugs.
6. Remove the ignition coil.
7. Remove the air chamber mounting bracket.
8. Remove the intake manifold.
9. Remove the heat shield and exhaust manifold.
10. Remove the water pump pulley and crankshaft pulley.
11. Remove the timing belt covers.
12. Move the timing belt tensioner roller toward the water pump and temporarily secure it in this position.
13. Remove the timing belt.
14. Remove the cylinder head cover.
15. Using a special tool, in the sequence shown in the figure, in 2–3 passes, unscrew the cylinder head mounting bolts.
16. Remove any remaining gasket from the cylinder head and block.
Note: Be careful not to allow gasket material particles to enter the engine cylinders.
Examination
1. Inspect the cylinder head for damage, cracks, oil and coolant leaks. Replace the cylinder head if necessary.
2. Remove scale, sealant and carbon deposits. Blow out lubrication channels with compressed air.
3. Using a metal ruler and feeler gauge in six directions A, B… check the flatness of the cylinder head. If necessary, regrind the cylinder head.
Standard deviation from flatness:
- 1.3L engine: less than 0.03mm
- 1.1L engine: less than 0.05mm
Maximum permissible deviation from flatness:
The article is borrowed from the website [HyundaiBook]
- 1.3L engine: less than 0.08mm
- 1.1L engine: less than 0.10 mm
Installation
1. Clean all mating surfaces of the cylinder block and cylinder head.
2. Install a new cylinder head gasket.
3. Tighten the cylinder head bolts in the sequence shown in the figure.
Tightening torque of mounting bolts
cylinder heads:
- 1.3L engine: 23–27 Nm + turn further by an angle of (60–62)° + turn further by an angle of (60–62)°
- 1.1L engine:
- on a cold engine: 60–70Nm
- on a hot engine: 70–75 N·m
4. Move the timing belt tensioner roller towards the water pump and secure it in this position.
5. Install the timing belt on the camshaft pulley and tighten the drive side of the belt by turning the pulley in the opposite direction to normal. Check that the timing marks are aligned.
6. Adjust the timing belt tension.
7. Install the cylinder head cover and tighten the mounting bolts to the specified torque.
Tightening torque: 8–10 Nm
8. Install the timing belt covers.
9. Install the new intake manifold gasket and intake manifold. Tighten the mounting bolts to the specified torque.
Tightening torque: 15–20 Nm
10. Install the new exhaust manifold gasket and exhaust manifold. Tighten the mounting nuts to the specified torque.
11. Install the air chamber and tighten the nuts and bolts to the specified torque.
Tightening torque: 15–20 Nm
12. Install the ignition coil.
13. Install the air intake pipe.
14. Connect the vacuum hose, fuel hose and coolant supply hose.
15. Connect the crankcase ventilation hose.