Hyundai Repair: hyundai 93 excel 1.5 l engine noise -cracked rod, valve cover gasket, rocker shaft

Question
HI! thanks so much for your response HT. you were right...we checked the timing and the pistons were all firing.
3 of the engine mount rubber disks are trashed so the engine was rocking... we listened to the engine with a pipe -"stethoscope"
and took of the top of the head to see a rod snapped in half!
(i think its called exhaust rocker mount rod mount; outer of 2 rods on either side of the camshaft holding the rockers)
We ran the car for a sec with 1 & 2 off and no lower knocking.
So if we get a new rod from a junkyard head what is the safest way of disassembling the springs and do we tighten each of 4 bolts in tandem to get it back on?? thanks for any insight!!!

Answer
It sounds like the exhaust rocker shaft is broken.  Usually this occurs after one of the bolts on the rocker shaft has come loose, allowing the pressure to bend the shaft and eventually break it.  Check the threads in the hole and make sure they're okay.  If not, you'll need to repair the threads or install a Helicoil or similar device.

On installation, simply swap the parts of the old rocker shaft and onto the new one, making certain to keep things in the same order and position.  Then, tighten down the new rocker shaft starting in the center and working out, tightening a little at a time as you go.  Once you have the rocker shaft installed, you'll need to adjust the valve clearances.  Last, replace the valve cover gasket and reinstall the valve cover.

I'm not sure whether you'll be able to obtain a rocker shaft at a junk yard, but you should be able to obtain one from the dealer at a reasonable price.

I do have some concern that you're asking questions about the simpler portions of this repair.  While I generally support people attempting their own repairs, the finer points of this repair (thread repair and valve adjustment), if done incorrectly, can cause other problems that will be expensive to repair.  This repair isn't particularly expensive, so it may be worthwhile to just have it done at a shop.  If you still decide you're going to attempt repairs on your own, I encourage you to go to www.hmaservice.com, register for a free account, and use the online shop manual available there.