How to get rocker cover bolts out and back safely.

Part 1 of 3: Getting to the head bolts

Materials Needed

• Eye protection
• Gloves
• Oil and coolant drain
• Parts cleaner or brake cleaner
• Shop rags
• Socket set and ratchet1: Drain the oil and coolant. Put on your eye protection and gloves and drain the oilfrom the vehicle.
  Make sure the vehicle can not be started by removing the negative cable from the battery. Next the coolant will need to be drained so it does not leak when the head bolts are loosened.
  Step 2: Clean valve cover. Use some of the parts cleaner or brake cleaner to clean up the valve cover and as much of the cylinder head as is reasonable.Remove valve cover. If necessary, remove other components to make the valve covers accessible, and start removing the bolts from the valve cover.
  Once all bolts are removed carefully removed the valve cover from the cylinder head. If any valve cover gasket material remains, remove it at this time and clean any excess oil from the edges. Set the valve cover aside carefully as it will be reused with a new gasket once repairs are completed.

  Part 2 of 3: Pushrod engine head bolt removal

  Materials Needed
  
  • Head bolt socket (if needed)
  • Numbered cardboard
  • Rubber hammer
  • Socket set and ratchetStep 1: Rocker arm and rocker removal. A pushrod engine has long pushrods that protrude through the cylinder head and attach to the rocker rail.
    The rocket arm will need to be loosened first. Many manufactures have a specific sequence for removal of the rocker arm bolts. After the rocker arm is removed, the rockers will be unbolted.
    Set all rocker arms aside in the order they were removed as they should go back to the cylinder they were removed from.Step 2: Remove the pushrods. Remove the pushrods one at a time from the cylinder head.
    Put them into a numbered piece of cardboard as the pushrods will go back into the same slot they came from.Step 3: Loosen head bolts. Use the ratchet begin to break the cylinder head bolts loose.
    Each bolt will be loosened but not removed. Loosen all of the bolts before removing any of the the bolts all the way.
    Step 4: Remove the bolts. Place each bolt through a numbered hole in the cardboard in case the head bolts are different lengths so they can be installed back into the proper hole.
    The bolts may require a special socket depending on the manufacture.
    Step 5: Lift off the cylinder head. Once all bolts are removed, lift up on the cylinder headgently; the head should come free easilyIf the cylinder head sticks, lightly use a dead blow or rubber mallet to tap the cylinder head to be able to remove it. Set to the side in a safe area.
    
    • Warning: Cylinder head bolts have a specific sequence that is used when removing them. Consult the manufacturer's specifications for the proper removal sequence for the engine being worked on.

    Part 3 of 3: Overhead cam head bolt removal

    Material Needed
    
    • Socket set and ratchetStep 1: Remove the timing cover. The timing cover will need to be removed to gain access to the timing belt or chain.
      This is necessary because the cam shaft sits in the cylinder head and is attached to the crankshaft with either a timing belt or timing chain.
      Step 2: Time the engine to remove the belt. The engine will need to be timed to avoid damage when the timing belt is removed.
      Each engine is different and will have its own procedures to time. There should be marks on the camshaft and crankshaft that will be aligned to set the timing at top dead center (TDC)Step 3: Remove the timing belt. The timing belt tensioner will be removed or released to take the tension off the belt.
      Once the belt is loosened, it should be able to be slipped of the camshaft in the cylinder head.Step 4: Remove the head bolts. Every engine will have its own procedures for the order that the head bolts are removed or tightened.
      Loosen head bolts ¼ turn each in the order specified, which may require a special socket. Once all the bolts have been loosened they may be removed one at a time. The bolts must be organized or marked in case they are different lengths.
      Step 5: Remove the cylinder head. Once all the bolts are removed, the cylinder head may be removed from the engine. If it is stuck, tap lightly on the side of the head with a rubber hammer to loosen the cylinder head.
      
      • Warning: Most head bolts are torque-to-yield. These head bolts are single use only and once removed must be replaced. Torque-to-yield head bolts stretch when they are torqued to allow them to tighten properly and repeated application can cause the head bolt to break.
      Removing the head bolts can seem like a daunting process

When you replace the rocker cover gaskets, clean the surfaces where the gasket contacts the heads and the rocker cover with alcohol and a rag. Make sure there is absolutely no oil residue on either surface. Use a silicon sealer and spread it on the side of the gasket that will touch the head. Position it and use the head bolts temporarily as guide pins to hold the gasket in place until the sealant dries COMPLETELY. Remove the bolts. Now put more sealant on the surface of the rocker cover and install the cover on the gasket gently so as not to disturb the gasket. Install the cover bolts and tighten firmly but not so as to squeeze or deform the gasket. If dine correctly, the gasket will not leak.

Unscrew the rocker cover and remove the top casing, most cars now have gasket seal rather than a gasket so check this. Put new gasket in place and then replace top casing, replacing the bolts back in the order they should be in, then put rocker cover back on...
HYUNDAI MATRIX 1 6L 2003 G4ED F4AF3

not specifically , but just snug it up then turn 1/4 turn

let me see if i can get some info 4 you.

edit
REMOVAL

1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (between the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover.


15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool, Cylinder Head Bolt Wrench (09221-32001) or equivalent, in the sequence as shown in the illustration in two or three steps.
16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: Make sure that the gasket pieces do not fall in the engine.

INSTALLATION

1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly. Apply sealant to the gasket and do not reuse the old cylinder head gasket.


3. Install the cylinder head bolts. Starting at top center, tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench (09221 - 32001) or equivalent. Repeat the procedure, re-tightening all cylinder head bolt to the specified torque. (torque spec is Cold Engine 105-115 Nm (76-83 ft lb) )
4. Install the timing belt tensioner pulley.
5. Install the timing belt on the camshaft sprocket, making sure that the tension side is tightened by turning the camshaft sprocket in reverse, all timing marks are in alignment.
6. Adjust the timing according to "Timing Belt"
7. Install the rocker cover and tighten the bolts to the specified torque. Tightening torque: Rocker cover belt:

2.5-3.5 Nm (25-35 kg.cm, 2-3 ft. lbs.)

8. Install the timing belt cover.
9. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
10. Install the new exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the specified torque.
11. Install the surge tank and tighten the nuts bolts to the specified torque.
12. Install the power steering oil pump and bracket.
13. Install the ignition coil.
14. Install the air intake hose.
15. Connect the vacuum hose, fuel hose and water hose.
16. Install breather hose.

cylinder head bolts 52-55 ft lbs. engine cold 59-63 ft lbs. engine hot

rocker arm shaft bolts 15-20 ft lbs.

intake manifold bolts 11-15 ft lbs.

exhaust manifold bolts 22-30 ft lbs.

valve cover bolts 79-81 in lbs.

The bolts should have thread lock on them when installing, and the torque is done in 2 steps. 33 ft lbs. and then 90 deg. after that on the second pass. 3.1L Engine CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. LEFT SIDE (FRONT)

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system into a suitable container.
4. Disconnect the top half of the air cleaner assembly, then remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Disconnect the spark plug wires from spark plugs and looms then route the wires out of the way.
7. Remove the rocker arm (valve) covers.
8. Remove upper intake plenum and lower intake manifold.
9. Remove the left side exhaust manifold.
10. Remove oil level indicator tube. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
11. Remove rocker arms nut, rocker arms, balls and pushrods.
12. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To install:
    
13. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
14. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
15. Coat the bolt threads lightly with sealer, then install finger-tight.
16. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
17. Install the pushrods, rocker arms, balls and rocker arm nuts in their proper locations. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
18. Install the lower intake manifold and upper intake plenum.
19. Install the rocker arm (valve) covers.
20. Install the oil level indicator tube. Insert the dipstick.
21. Connect the spark plug wires to spark plugs and looms.
22. Install the left side exhaust manifold.
23. Install the exhaust crossover pipe and heat shield.
24. Refill the cooling system.
25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
26. Connect negative battery cable.
27. Start vehicle and verify that there are no leaks. Fig. 20: Cylinder head mounting and bolt tightening sequence - 3.1L engine
    

RIGHT CYLINDER HEAD (REAR) CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Raise and safely support the vehicle.
7. Detach the Oxygen (O2) sensor connector.
8. Disconnect the exhaust pipe from the exhaust manifold.
9. Remove the right side exhaust manifold.
10. Carefully lower the vehicle.
11. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
12. Remove the rocker arm (valve) covers.
13. Remove upper intake plenum and lower intake manifold. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
14. Remove rocker arms nut, rocker arms, balls and pushrods.
15. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To Install:
    
16. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
17. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP showing.
18. Coat the bolt threads lightly with sealer, then install finger-tight.
19. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
20. Install the pushrods loosely retained with the rocker arm assemblies. Make sure all pushrods are in the correct locations. Coat the ends of the pushrods with prelube. The intake rods are marked yellow and are 5 3?4 inch long. The exhaust pushrods are marked green and 6 inches long. balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
21. Install the lower intake manifold and upper intake plenum.
22. Install the rocker arm (valve) covers.
23. Connect the spark plug wires to spark plugs and wire looms.
24. Raise and safely support the vehicle.
25. Install the exhaust manifold.
26. Connect the exhaust pipe to the exhaust manifold.
27. Carefully lower the vehicle.
28. Connect the Oxygen (O2) sensor wiring.
29. Install the exhaust crossover pipe and heat shield.
30. Refill the cooling system.
31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
32. Connect negative battery cable.
33. Start vehicle and verify that there are no leaks.

Cylinder Head Removal & Installation To Remove:

1. Remove the intake manifold.
2. Remove the timing belt.
3. Disconnect the exhaust pipe from the manifold.
4. Remove the water outlet pipe and o-rings.
5. Remove the water passage assembly.
6. Remove the water pipe assembly.
7. Remove the breather hose and spark plug cables from the rocker covers.
8. Remove the rocker cover.
9. Disconnect the camshaft position sensor connector.
10. Loosen the cylinder head mounting bolts in 3 steps, using the reverse of the installation sequence. Lift the cylinder head assembly and remove the head gasket.

To Install:

1. Clean the engine and cylinder head sealing surfaces.
2. Install the new gasket on the engine with the identification mark facing up and to the front.
3. Using 3 even steps, torque the head bolts in sequence, to 76-83 ft-lbs. (105-115 Nm). Cylinder head bolt tightening sequence
   
4. Connect the camshaft position sensor connector.
5. Install the rocker cover.
6. Install the breather hose and spark plug cables from the rocker covers.
7. Install the water pipe assembly.
8. Install the water passage assembly.
9. Install the water outlet pipe and o-rings.
10. Disconnect the exhaust pipe from the manifold.
11. Install the timing belt.
12. Install the intake manifold.

2.2L (VIN 4) Engine

1. Before servicing the vehicle, refer to the precautions section.
   
2. Relieve the fuel system pressure.
   
3. Drain the cooling system.
   
4. Remove or disconnect the following:
   
   • Accessory drive belt
     
   • Air cleaner outlet duct
     
   • Engine mount
     
   • Intake manifold
     
   • Exhaust manifold
     
   • Engine Coolant Temperature (ECT) sensor electrical connector
     
   • Power steering pump
     
   • Radiator inlet pipe
     
   • Spark plug wires
     
   • Rocker arm cover
     
   
   NOTE Whenever valve train components are removed, keep them in order for installation purposes.
   
   
   • Rocker arms and pushrods
     
   • Lifters
     
   • Alternator rear brace and the alternator
     
   • Power steering pump
     
   • Radiator inlet pipe
     
   • Ignition coil assembly
     
   • Accessory bracket
     
   • Spark plug wires
     
   • Cylinder head bolts
     
   
   WARNING Two sizes of bolts are used; note the location of each.
   
   
   • Cylinder head
     
5. Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
   

Cylinder head torquing sequence—2.2L (VIN 4) engine

1. Install or connect the following:
   
   • Cylinder head with a new gasket and new cylinder head bolts. Torque the long bolts, in sequence to 46 ft. lbs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm) plus an additional 90 degree turn on all the bolts.
     
   • Lifters
     
   • Pushrods and rocker arms. Torque nuts to 22 ft. lbs. (30 Nm).
     
   • Rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
   • Spark plug wires
     
   • Accessory bracket
     
   • Ignition coil assembly
     
   • Radiator inlet pipe
     
   • Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
   • ECT sensor electrical connector
     
   • Exhaust manifold. Torque the nuts to 118 inch lbs. (13 Nm).
     
   • Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
   • Intake manifold. Torque the bolts to 17 ft. lbs. (24 Nm).
     
   • Engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     
   • Air cleaner outlet duct
     
   • Accessory drive belt
     
   • Negative battery cable
     
2. Refill and bleed the cooling system.
   
3. Start the vehicle and inspect for leaks.
   

This is All you need for this Repair, ALSO Be Sure ALL GASKET SURFACES ARE VERY CLEAN. This Engine Requires MORE than MOST ALL Engines do for this Repair.

REMOVAL

1. To remove a valve rocker arm cover from the RH cylinder head, disconnect PCV closure tube from oil fill stand pipe at rocker cover.
2. Remove the Thermactor bypass valve and air supply hoses as necessary to provide clearance.
3. Disconnect the spark plug wires from the spark plugs using Spark Plug Wire Remover T74P-6666-A or equivalent. Do not pull on wire. Remove the wires and bracket assembly from the rocker arm cover attaching stud and position the wires out of the way. ALSO MARK THEM AS TO WHERE THEY CAME FROM !!!
4. Remove upper intake manifold.
5. Remove attaching bolts and remove the cover.

INSTALLATION

1. Clean the valve rocker arm cover(s) and the cylinder head gasket surface(s). Position a new service valve rocker cover gasket.
2. Position the cover(s) on the cylinder head(s). The cover is tightened in two steps. Tighten the bolts to 14-18 N.m (10-13 lb-ft). Two minutes later, tighten the bolts to the same specification.
3. Install the crankcase ventilation tube in the RH cover.
4. Install upper intake manifold.
5. Install the spark plug wires and bracket assembly on the rocker arm cover attaching stud. Connect the spark plug wires. Install the air intake duct assembly.
6. Install the Thermactor bypass valve and air supply hoses (if required).