| TIBURON(GK) >2004 > G 2.0 DOHC > Engine Mechanical System > General Information>General Information |

SPECIFICATIONS
Description | Specification | Limit
General Type Number of cylinder Bore Stroke Total displacement Compression ratio Firing order | In-line, Double overhead Camshaft 4 82mm (3.228 in.) 93.5mm (3.681in.) 1975cc (120.52 cu.in.) 10.1 1-3-4-2 |
Valve timing(W/O-CVVT) Intake valve Opens (BTDC) Close (ABDC) EXhaust valve Opens (BBDC) Close (ATDC) Valve timing (W-CVVT) Intake valve Opens (ATDC) Closes (ABDC) Exhaust Opens (BBDC) Close (ATDC) | 9° 43° 50° 6° 11° 59° 42° 6 |
Valve Valve length Intake Exhaust Stem O.D. Intake Exhaust | 114.34mm (4.5016in.) 116.8mm (4.5984in.) 5.965 ~ 5.98mm (0.2348 ~ 0.2354in.) 5.950 ~ 5.965mm (0.2343 ~ 0.2348in.) |
Face angle thickness of valve head (Margin) Intake Exhaust Valve stem to valve guide clearance Intake Exhaust | 1.15mm (0.0452in.) 1.35mm (0.0531in.) 0.02 ~ 0.05mm (0.0008 ~ 0.0019in.) 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.) | 0.8mm (0.031in.) 1.0mm (0.039in.) 0.10mm(0.0039in.) 0.13mm(0.0051in.)
Valve guide Intake Exhaust Service oversize | 46mm (1.811in.) 54.5mm (2.146in.) 0.025, 0.25, 0.50mm (0.002, 0.010, 0.020in.) oversize |
Valve seat Width of seat contact Intake Exhaust Seat angle Oversize | 1.1 ~ 1.5mm (0.043 ~ 0.059in.) 1.3 ~ 1.7mm (0.051 ~ 0.066in.) 45° 0.3, 0.6mm (0.012, 0.024in.) oversize |
Valve spring Free length Load Installed height Squareness | 48.86mm (1.9236in.) 18.3kg / 39mm, 40.0kg / 30.5mm 39mm (1.5344in.) 1.5° or less |
Valve clearance (cold) Intake Exhaust Hot [80°C (176°F)] : only for reference Intake Exhaust | 0.20mm (0.0079in.) 0.28mm (0.0110in.) 0.29mm (0.0114in.) 0.34mm (0.0134in.) | 0.12 ~ 0.28mm (0.0047 ~ 0.0110in.) 0.20 ~ 0.38mm (00.0079 ~ 0.0150in.)
Cylinder head Flatness of gasket surface Flatness of manifold mounting surface Oversize rework dimensions valve seat hole Intake 0.3mm (0.012in.) O.S. 0.6mm (0.024in.) O.S. Exhaust 0.3mm (0.012in.) O.S. 0.6mm (0.024in.) O.S. Oversize rework dimensions of valve guide hole (both intake and exhaust) 0.05mm (0.002 in.) O.S. 0.25mm (0.010in.) O.S. 0.50mm (0.020in.) O.S. | Max. 0.03mm (0.0012in.) Max. 0.15mm (0.0110 in.) 33.300 ~ 33.325mm (1.3110 ~ 1.3120in.) 33.600 ~ 33.625mm (1.3228 ~ 1.3238in.) 28.800 ~ 28.821mm (1.1338 ~ 1.1346in.) 29.100 ~ 29.121mm (1.1456 ~ 1.14665in.) 11.05 ~ 11.068mm (0.435 ~ 0.4357in.) 11.25 ~ 11.268mm (0.443 ~ 0.4436in.) 11.50 ~ 11.518mm (0.453 ~ 0.4535in.) | 0.06mm (0.0024in.) Max. 0.03mm (0.0118in.)
Cylinder block Cylinder bore Out-of-round taper of cylinder bore Clearance with piston (To set limits to new parts) | 82.00 ~ 82.03mm (3.2289 ~ 3.2295in.) Less than 0.01mm (0.0004in.) 0.02 ~ 0.04mm (0.0008 ~ 0.0016in.) |
Piston O.D. (To set limits to new parts) Service oversize | 81.97 ~ 82.00mm (3.2271 ~ 3.2283in.) 0.25, 0.50mm (0.010, 0.020in.) oversize |
Piston ring Side clearance No. 1 No. 2 End gap No. 1 No. 2 Oil ring side rail Service oversize | 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.23 ~ 0.38mm (0.0090 ~ 0.0149in.) 0.33 ~ 0.48mm (0.0130 ~ 0.0189in.) 0.20 ~ 0.60mm (0.0078 ~ 0.0236in.) 0.25, 0.50mm (0.010, 0.020in.) oversize | 0.1mm (0.004in.) 1mm (0.039in.) 1mm (0.039in.) 1mm (0.039in.)
Connecting rod bearing Bend Twist Connecting rod big end to crankshaft side clearance | 0.05mm (0.0020in.) or less 0.1mm (0.004in.) or less 0.100 ~ 0.250mm (0.0039 ~ 0.0098in.) | 0.04mm (0.0157in.)
Connecting rod bearing Oil clearance (To set limits to new parts) Undersize | 0.024 ~ 0.044mm (0.0009 ~ 0.0017in.) 0.25, 0.50, 0.75mm (0.01, 0.20, 0.03 in.) |
Camshaft (W/O-CVVT) Cam lobe height Intake Exhaust Camshaft (W-CVVT) Cam lobe height Intake Exhaust Journal O.D. Bearing oil clearance End play | 44.820mm (1.7646in.) 44.720mm (1.7606in.) 44.618mm (1.7566in.) 44.518mm (1.7527in.) 28mm (1.1023in.) 0.02 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.1 ~ 0.2mm (0.004 ~ 0.008in.) | 44.720mm (1.7606in.) 44.620mm (1.7567in.) 44.518mm (1.7527in.) 44.418mm (1.7487in.) 0.1mm (0.0039in.)
Crankshaft Pin O.D. Journal O.D. Bend Out-of-round, taper of journal and pin End play Undersize rework dimension of pin 0.25mm (0.010in.) 0.50mm (0.020in.) 0.75mm (0.030in.) Undersize rework dimension of journal 0.25mm (0.010in.) 0.50mm (0.020in.) 0.75mm (0.030in.) | 45mm (1.77in.) 57mm (2.244in.) 0.03mm (0.0012in.) or less 0.01mm (0.0004in.) or less 0.06 ~ 0.260mm (0.0023 ~ 0.010in.) 44.725 ~ 44.740mm (1.7608 ~ 1.7614in.) 44.475 ~ 44.490mm (1.7509 ~ 1.7516in.) 44.225 ~ 44.250mm (1.7411 ~ 1.7517in.) 56.727 ~ 56.742mm (2.2333 ~ 2.2339in.) 56.477 ~ 56.492mm (2.2235 ~ 2.2240in.) 56.227 ~ 56.242mm (2.2136 ~ 2.2142in.) | 0.30mm (0.0118in.)
Flywheel Runout | 0.1mm (0.0039in.) | 0.13mm (0.0051in.)
Cooling method | Water-cooled, pressurized, Forced circulation with electrical |
Coolant Quantity | 6 liter (6.3U.S qts., 5.2lmp. qts) |
Radiator Type | Pressurized corrugated fin type |
Radiator cap Main valve opening pressure Vacuum valve opening temperature | 83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kg/cm²) -7kpa (-1.00psi, -0.07kg/cm²) |
Thermostat Type Valve opening temperature Full-opening temperature | Wax pellet type with jiggle valve 82°C (177°F) 95°F (201°F) |
Coolant pump | Centrifugal type impeller |
Driver belt Type | V-ribbed belt |
Engine coolant temperature sensor Type Resistance | Heat-sensitive thermistor type 2.31 ~ 2.59KΩ at 20°C (68°F) |
Oil pump Clearance between outer circuference and front case Front clearance Side clearance Inner gear Outer gear Engine oil pressire at 15rpm [Oil temperature is 90 to 110°C (194 ~ 230°F] | 0.120 ~ 0.185mm (0.0047 ~ 0.0073in.) 0.025 ~ 0.069mm (0.0009 ~ 0.0027in.) 0.04 ~ 0.085mm (0.0016 ~ 0.0033in.) 0.04 ~ 0.09mm (0.0016 ~ 0.0035in.) 245KPa (2.5kg/cm², 35.5psi) |
Relief spring Free height Load | 43.8mm (1.724in.) 3.7kg at 40.1mm (3.15lb/1.578in.) |
Air cleaner Type Element | Dry type Unwoven cloth type |
Exhaust pipe Muffler Suspension system | Expansion resonance type Rubber hanger |
SERVICE STANDARDS
Standard value
Antifreeze | Maxture ratio of anti-freeze in coolant
ETHYLENE GLOYCOL BASE FOR ALUMINUM | 50%
TIGHTENING TORQUE
Item | Nm | kg.cm | Lb.ft
Cylinder Block Front engine support bracket bolt and nut Front roll stopper bracket bolt Rear roll stopper bracket bolt Rear engine stopper bracket bolt | 35 ~ 50 70 ~ 90 70 ~ 90 35 ~ 50 | 350 ~ 500 700 ~ 900 700 ~ 900 350 ~ 500 | 25 ~ 37 51 ~ 65 51 ~ 35 25 ~ 38
Engine Mounting Right mounting insulator (large) nut Right mount insulator (small) nut Right mounting bracket to engine nuts and bolts Transmission mount insulator nut Transmission insulator bracket to side member bolts Rear roll stopper insulator nut Rear roll stopper bracket to center member bolts Front roll stopper insulator nut Front roll stopper bracket to center member bolts | 90 ~ 110 45 ~ 60 50 ~ 65 90 ~ 110 40 ~ 50 50 ~ 65 40 ~ 50 50 ~ 65 40 ~ 50 | 900 ~ 1100 450 ~ 600 500 ~ 650 900 ~ 1100 400 ~ 500 500 ~ 650 400 ~ 500 500 ~ 650 400 ~ 500 | 65 ~ 80 33 ~ 44 36 ~ 48 65 ~ 80 30 ~ 36 36 ~ 48 30 ~ 36 36 ~ 48 30 ~ 36
Main Moving Connecting rod cap nut Crankshaft bearing cap bolt Fly wheel M/T bolt Drive plate A/T bolt Engine cover Chain guide Heat protector Water pipe bracket bolts | 50 ~ 53 27~33+(60°~65°) 120 ~ 130 120 ~ 130 4 ~ 6 8 ~ 10 15 ~ 20 12 ~ 15 | 500 ~ 530 270~330+(60°~65°) 1200 ~ 1300 1200 ~ 1300 40 ~ 60 80 ~ 100 150 ~ 200 120 ~ 150 | 36 ~ 39 20~24+(60°~65°) 88 ~ 95 88 ~ 95 3 ~ 4 6 ~ 7 11 ~ 15 9 ~ 11
Cooling system Alternator support bolt and nut Alternator lock bolt Alternator brace mounting bolt Coolant pump pulley bolts Coolant pump bolts Coolant temperature sensor Coolant inlet fitting nuts Thermostat housing bolts and nuts | 20 ~ 25 15 ~ 15 20 ~ 27 8 ~ 40 20 ~ 27 20 ~ 40 15 ~ 20 15 ~ 20 | 200 ~ 250 120 ~ 150 200 ~ 270 80 ~ 400 200 ~ 270 200 ~ 400 150 ~ 200 150 ~ 200 | 14 ~ 18 8 ~ 11 15 ~ 20 6 ~ 7 14 ~ 19 15 ~ 30 11 ~ 14 11 ~ 14
Lubrication system Oil filter Oil pan bolts Oil pan drain plug Oil screen bolts Oil pressure switch | 12 ~ 16 10 ~ 12 40 ~ 45 15 ~ 22 13 ~ 15 | 120 ~ 160 100 ~ 120 400 ~ 450 150 ~ 220 130 ~ 150 | 9 ~ 12 7 ~ 9 30 ~ 33 11 ~ 16 9.7 ~ 11
Intake and Exhaust system Air cleaner body mounting bolts Resonator mounting bolts Intake manifold to cylinder head nuts and bolts Intake manifold to cylinder block bolts Throttle body to surge tank nuts Exhaust manifold to cylinder head nuts Exhaust manifold cover to exhaust manifold bolts Oxygen sensor to front muffler Oxygen sensor to exhaust manifold Front exhaust pipe to exhaust manifold nuts Front exhaust pipe to catalytic converter bolts Main muffler hanger support bracket bolts | 8 ~ 10 4 ~ 6 16 ~ 23 18 ~ 25 15 ~ 20 43 ~ 55 15 ~ 20 50 ~ 60 30 ~ 40 30 ~ 40 40 ~ 60 10 ~ 15 | 80 ~ 100 40 ~ 60 160 ~ 230 180 ~ 250 150 ~ 200 430 ~ 550 150 ~ 200 500 ~ 600 300 ~ 400 300 ~ 400 400 ~ 600 100 ~ 150 | 6 ~ 7 3 ~ 4 12 ~ 17 13 ~ 18 11 ~ 14 32 ~ 40 11 ~ 14 36 ~ 43 22 ~ 29 22 ~ 29 29 ~ 43 7 ~ 11
Cylinder head Cylinder head bolt - M10 Cylinder head bolt - M12 Inatake manifold nuts Exhaust manifold nuts Cylinnder head cover bolts Camshaft bearing cap bolts Oil control valve bolt OCV filter CVVT assembly to exhaust camshaft bolt Rear plate bolts | 25 + (60~65°) + (60°~65°) 30 + (60~65°) + (60°~65°) 18 ~ 25 43 ~ 55 8 ~ 10 14 ~ 15 10 ~ 12 41 ~ 51 66 ~ 78 8 ~ 10 | 250 + (60~65°) + (60°~65°) 300 + (60~65°) + (60°~65°) 180 ~ 250 430 ~ 550 80 ~ 100 140 ~ 150 100 ~ 120 410 ~ 510 660 ~ 780 80 ~ 100 | 18 + (60~65°) + (60°~65°) 22 + (60~65°) + (60°~65°) 13 ~ 18 32 ~ 41 6 ~7 10 ~11 7.3 ~8.8 30 ~37.6 48.7 ~ 57.5 6 ~ 7
Timing belt Crankshaft pulley bolt Camshaft sprocket bolt Timing belt tensioner bolts Timing belt cover bolts Front case bolts Timing belt idler bolt | 170 ~ 180 100 ~ 120 43 ~ 55 8 ~ 10 20 ~ 27 43 ~ 55 | 1700 ~ 1800 1000 ~ 1200 430 ~ 550 80 ~ 100 200 ~ 270 430 ~ 550 | 125 ~ 133 74 ~ 89 31 ~ 40 6 ~ 7 14 ~ 20 31 ~ 40
M/T : Manual Transmission A/T : Automatic Transmission MAINTENANCE CHECKING ENGINE OIL
1. | Position the vehicle on a level surface.
2. | Warm up the engine.
If the vehicle has been out of service for a prolonged period of time, warm up the engine for approximately 20 minutes.
3. | Turn off the engine, and wait 2 or 3 minutes, then check the oil level.
4. | Check that the engine oil level is within the level range indicated on the oil dipstick. If the oil level is found to have fallen to the lower limit (the "L"mark), refill to the "F" mark.
When refilling, use the same type of engine oil.
5. | Check that the oil is not dirty or contaminated with coolant or gasoline, and that it has the proper viscosity.
CHANGING ENGINE OIL
Be careful not to burn yourself, as the engine oil is hot.
1. | Run the engine until it reaches normal operating temperature.
2. | Turn off the engine.
3. | Remove the oil filler cap and the drain plug (on the oil pan). Drain the engine oil.
4. | Install and tighten the drain plug to the specified torque.
Tightening torque Drain plug : 40 ~ 45 Nm (400 ~ 450 kg.cm, 30 ~ 33 lb.ft)
5. | Fill the crankcase with fresh engine oil through the oil filler cap opening.
Capacity Drain and refill Without oil filter : 3.55 liter (3.75 U.S.qts., 3.1 lmp.qts.) With oil filter : 3.85 liter (4.1 U.S.qts., 3.4 lmp.qts.)
Do not overfill the crankcase. This will cause oil aeration and loss of oil pressure.
6. | Install the oil filler cap.
7. | Start and run the engine.
8. | Turn off the engine and then check the oil level. Add oil if necessary.
FILTER SELECTION All Hyundai engines are equipped with a high quality, disposable oil filter. This filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is completely removed from the contact surface on the engine block or front case before installing the new filter. PROCEDURE FOR REPLACING THE OIL FILTER
Be careful not to burn yourself, as the engine and engine oil are hot.
1. | Use a filter wrench to remove the oil filter.
2. | Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
3. | Tighten the oil filter to the specified torque.
Tightenin torque Oil filter : 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)
4. | Run the engine to check for engine oil leaks.
5. | After turning off the engine, check the oil level and add oil as necessary.
SELECTION OF ENGINE OIL Recommended API classification: SH OR ABOVE Recommended SAE viscosity grades : W/O - CVVT W - CVVT
1. | Satisfy the requirements of the API classification.
2. | Have proper SAE grade number for expected ambient temperature range.
CHECKING COOLANT LEAK
1. | Loosen the radiator cap.
2. | Confirm that the coolant level is up to the filler neck.
3. | Install a radiator cap tester to the radiator filler neck and apply 140 KPa (1.4 kg/cm², 20psi ) pressure. Hold it for two minutes in that condition, while checking for leakage from the radiator, hoses or connections.
1. | Radiator coolant may be extremely hot. Do not open the system because hot, or scalding water could gush out causing personal injury. Allow the vehicle to cool before servicing this system.
2. | Be sure to clean away any moisture from the places checked completely.
3. | When the tester is removed, be careful not to spill any coolant from it.
4. | Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator.
4. | If there is leakage, repair or replace with the apropriate part.
RADIATOR CAP PRESSURE TEST
1. | Use an adapter to attach the cap to the tester.
2. | Increase the pressure until the gauge stops moving.
Main valve opening pressure : 83 ~ 110 kPa (0.83 ~ 1.1 kg/cm², 12 ~ 16 psi) Vacuum valve opening pressure : -7 kPa (-0.07 kg/cm², -1.0 psi)
3. | Check that the pressure level is maintained at or above the limit.
4. | Replace the radiator cap if the reading does not remain at or above the limit.
Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrectreading.
SPECIFIC GRAVITY TEST
1. | Measure the specific gravity of the coolant with a hydrometer.
2. | Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference. RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C(°F) and specific gravity | Freezing temperature °C (°F) | Safe operating temperature °C(°F) | Coolant concentration (specific volume)
10 (50) | 20 (68) | 30 (86) | 40 (104) | )
1.504 | 1.050 | 1.046 | 1.042 | 1.036 | -16 (3.2) | -11 (12.2) | 30%
1.063 | 1.058 | 1.054 | 1.049 | 1.044 | -20 (-4) | -15 (5) | 35%
1.071 | 1.067 | 1.062 | 1.057 | 1.052 | -25 (-13) | -20 (-4) | 40%
1.079 | 1.074 | 1.069 | 1.064 | 1.058 | -30 (-22) | -25 (-13) | 45%
1.087 | 1.082 | 1.076 | 1.070 | 1.064 | -36 (-32.8) | -31 (-23.8) | 50%
1.095 | 1.090 | 1.084 | 1.077 | 1.070 | -42 (-44) | -37 (-35) | 55%
1.103 | 1.098 | 1.092 | 1.084 | 1.076 | -50 (-58) | -45 (-49) | 60%
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F)
• | If the concentration of the coolant is below 30%, its anti-corrosion properties will be adversely affected.
• | If the concentration is above 60%, both the anti-freeze and engine cooling property will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range
• | Do not use together with another brand's product.
RECOMMENDED COOLANT
Antifreeze | Mixture ratio of anti freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM | 50% [Except tropical areas] 40% [Tropical areas]
CHECKING COMPRESSION PRESSURE
1. | Before checking engine compression, check the engine oil level. Also check that the starter motor and battery are all in normal operating condition.
2. | Start the engine and wait until engine coolant temperature reaches 80 ~ 95°C (176 ~ 205°F).
3. | Turn off engine and disconnect the spark plug cables.
4. | Remove the spark plugs.
5. | Crank the engine to remove any foreign material in the cylinders.
6. | Insert the compression gauge into the spark plug hole.
7. | Depress the accelerator pedal to open the throttle fully.
8. | Crank the engine and read the gauge.
Standard value : 1500kpa (15Kg/cm², 218 psi) Limit : 1400kpa (14Kg/cm², 203 psi)
9. | Repeat steps 6 to 8 over all cylinders, ensuring that the pressure differential for each of the cylinders is within the specified limit.
Limit Max. 100 kpa (1.0 kg/cm² ,14 psi) between cylinder
10. | If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil through the spark plug hole, and repeat steps 6 to 9.
(1) | If the addition of oil makes the compression to rise, it is likely that there may be wear between the piston ring and cylinder wall
(2) | If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes.
Tightening torque Spark plug : 20 ~ 30 Nm (200 ~ 300 kg.cm, 14 ~ 22 lb.ft)
Timing belt tension adjustment
1. | Remove the engine cover.
2. | Remove RH front wheel.
3. | Remove the 4bolts and timing belt upper cover.
4. | Turn the crankshaft pulley and align its groove with timing mark "T" of the timing belt cover.
5. | Temperarily loosen tensioner pulley by center bolt.
6. | Tming belt tension adjusting.
(1) | Rotate crankshaft in regular direction (clockwise view from front) through angle equivalent to two teeth (18°) of the camshaft sprocket.
(2) | Give tension to timing belt rotating tensioner in arrow diection tool and set timing belt not to give slack to tensioner side.
(3) | Tightening tensioner bolt.
Tightening torque Tensioner bolt : 43 ~ 55Nm (430 ~ 550kg.cm, 32 ~ 40lbf.ft)
(4) | Recheck the belt tension, when the tension side of timing belt is pushed horzontally with a moderate force [approx. 2kg (20N, 5lb)], the timing belt cog end segs in approx. 4 ~ 6mm (0.16 ~ 0.24in.).
7. | Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.
8. | Install the timing belt upper cover with 4bolts.
9. | Install RH front wheel.
10. | Install engine cover with 5bolt