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Hyundai i40 Rocker Cover Injector Replacement

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Hi guys,

Firstly, apologies if this is posted in the wrong forum. Mods, please feel free to move to the correct place!

Having owned several Skoda's, 7 in total, for many years, I bought an i40 as I needed a car quickly about 18 months ago.

It currently needs a new injector and rocker cover.

I have a really good local garage, amazing in fact, although they couldn't source a rocker cover anywhere.

I had the car recovered to my house.

So far, the rocker cover is off and the injectors removed - by my garage.

One injector is goosed and a hole has been burned in the rocker cover, as a result of the injector issue.

If I can source the parts, can anyone tell me exactly what I need?

Needless to say, I need a rocker cover and recon injector. It is more about the seals etc. Do I just need an injector seals kit? Or do I need additional items?

Watched a few videos, so I have a fair idea of what is required to replace the rocker cover/injector. Just want to be sure that I have all of the kit. That said, any pointers to relevant videos would be gratefully received!

Used this site many times for sage advice, so hoping for the same again.

Alternatively, willing to pay a reasonable amount for fitting if any competent DIYers are nearby in the Scottish Borders.

Thanks in advance,

Joe.

Edited by joeninho
Additional info

  • Author

Updated to say that I am fairly confident in general maintenance. Replacing discs, pads, calipers, wiper motors, window regulators, fuel filters, DPF sensors etc.

Far from an expert, but always willing to give it a go!

  • Author

@Breezy_Pete

@J.R.

Apologies for the tag, guys.

You have both been super helpful over the years, so I thought I would chance my arm!

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No idea, never touched a Hyundai.

J.R. hasn't been on here in several months, not since last August.

I’m not sure why a rocker cover should be so hard to get hold of. Are you looking for new or second hand?

Can it be repaired?

How old is the car?

What material is the rocker cover made of? how big is the hole in it?

  • Author

The car is a 2012 2.7crdi. It's in really good order other than this issue, so ideally I would like to repair it and save a few quid.

Missus currently pestering me to pick up another car, as we live in the middle of nowhere and we are sharing a car. First world problems!

I will post a photo of the rocker cover/injectors.

  • Author

A few picks of the rocker cover. Under close inspection, I can't see any major holes, so I assume the issue is the tiny hole at the injector housing.

IMG_20260404_144559149_HDR.jpg

IMG_20260404_144603425.jpg

IMG_20260404_144542674_HDR.jpg

  • Author

Here are the injectors...

Why is one different to the others?

Many thanks,

Joe.

IMG_20260404_144818770.jpg

I'd suggest trying to repair the hole if it's the one I see near the edge of the opening.

That 4th injector doesn't look right - are you certain it came from your engine?

  • Author

Thanks Warrior. Much appreciated.

I can't be certain that the 4th one came from my car. One of them was stuck and it took them some time to remove it. They said that the faulty one was knackered, as it was stuck.

I just got a box with all the parts. Perhaps they had tried that other one as they had it on hand.

How would I go about repairing the hole?

From the image, I doubt If that odd injector would even fit!

Something more than a bit odd going on there, it doesn't even look the correct length to reach into the cylinder!

If the cover is plastic, I'd try something like a plastic welding stick - or possibly an epoxy filler if the area is not required to be flexible.

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