TIBURON(GK) >2003 > 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)



43°

50°



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