TIBURON(GK) >2006 > G 2.0 DOHC > Engine Mechanical System > General Information>General Information  
SPECIFICATIONS
Description
Specifications
Limit
General
Type
Number of cylinder
Bore
Stroke
Total displacement
Compression ratio
Firing order

In-line, Double Overhead Camshaft
4
82mm (3.228in)
93.5mm (3.681in.)
1975cc (120.52cu.in.)
10.1
1-3-4-2

Valve timing
Intake valve
Opens (ATDC)
Closes (ABDC)
Exhaust
Opens (BBDC)
Closes (ATDC)


11°
59°

42°


Valve
Valve length
Intake
Exhaust
Stem O.D.
Intake
Exhaust


114.34mm (4.5016in.)
116.8mm (4.598in.)

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


1.15mm (0.0452in.)
1.35mm (0.0531in.)


0.8mm (0.031in.)
1.0mm (0.039in.)
Valve stem to valve guide clearance
Intake
Exhaust

0.02 ~ 0.05mm (0.0008 ~ 0.0019in.)
0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)

0.10mm (0.0039in.)
0.13mm (0.0051in.)
Valve guide
Installed dimension O.D
Intake
Exhaust
Service oversize



46mm (1.811in.)
54.5mm (2.146in.)
0.05, 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
Squarences

48.86mm (1.9236in.)
18.8kg/39mm (41.45lb/1.535in.)
39mm (1.5354in.)
1.5° MAX.

Valve clearance
Cold (20°C[68°F])
Intake

Exhaust


0.20mm (0.0079in.)

0.28mm (0.0110 in,)



0.12 ~ 0.28mm
(0.0047 ~ 0.0110in.)
0.20 ~ 0.38mm
(0.0079 ~ 0.0150in.)
Cylinder head
Flatness of gasket surface
Flatness of manifold mounting surface
Oversize rework dimensions of 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 (0.002in.) O.S
0.25mm (0.010in.) O.S
0.50mm (0.020in.) O.S

Max. 0.03mm (0.0012in.)
Max. 0.15mm (0.0059in.)



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 ~ 1.1465in.)


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.)
0.03mm (0.0012in.)
Cylinder block
Cylinder bore
Out-of-round and taper of cylinder bore
Clearance with piston
(To set limits to new parts)

82.00 ~ 82.03mm (3.2283 ~ 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.)
0.45 ~ 0.60mm (0.0177 ~ 0.0236in.)
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
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 ~ 0.010in.)



0.4mm (0.0157in.)
Connecting rod bearing
Oil clearance (To seat limits to new parts)
Undersize

0.024 ~ 0.042mm (0.0009 ~ 0.0016in.)
0.25mm (0.01in.)

Camshaft
Cam height
Intake
Exhaust
Jourmal O.D.
Bearing oil clearance
End play


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.)


44.518mm (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.)
Undersize rework dimension of journal
0.25mm (0.010in.)

45mm (1.77in.)
57mm (2.244in.)
0.03mm (0.0012in.) or less
0.005mm (0.0002in.) or less
0.06 ~ 0.260mm (0.0023 ~ 0.010in.)

44.725 ~ 44.740mm (1.7608 ~ 1.7614in.)

56.727 ~ 56.742mm (2.2333 ~ 2.2339in.)




0.030mm (0.0012in.)
Crankshaft bearing
Oil clearance

0.028 ~ 0.046mm (0.0011 ~ 0.0018in.)

Flywheel
Runout

0.1mm (0.0039in.)

0.13mm (0.0051in.)
Cooling method
Water-cooled, pressurized. Forced circulation with electrical fan

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 pressure

83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kg/cm²)
-7kpa (-100psi, -0.07kg/cm²) or less

Thermostat
Type
Valve opening temperature
Full-opening temperature

Wax pellet type with jiggle valve
82°C (177°F)
95°C (201°F)

Coolant pump
Centrifugal type impeller

Drive 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 circumference and front case.
Front case tip clearance
Side clearance
Inner gear
Outer gear
Engine oil pressure at 1500 RPM
[Oil temperature is 90 to 110°C (194 to 230°F)]

0.120 ~ 0.185mm (0.0049 ~ 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 (1.725in.)
3.7±0.4kg at 40.1mm (3.15±0.88lb/1.578in.)

Air cleaner
Type
Element

Dry type
Unwoven cloth type

Exhaust pipe
Muffler
Suspension system

Expansion resonance type
Rubber hangers


SERVICE STANDRDS
Standard value
Antifreeze
Maxture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM
50%

TIGHTENING TORQUE
Item
Nm
kgf.cm
lbf.ft
Cylinder Block
Front engine support bracket bolt and nut
Front roll stopper bracket bolt
Rear roll stopper bracket bolt
Rear engine support bracket bolt

35 ~ 50
70 ~ 90
70 ~ 90
40 ~ 50

350 ~ 500
700 ~ 900
700 ~ 900
400 ~ 500

25 ~ 37
51 ~ 65
51 ~ 65
30 ~ 37
Engine Mounting
Right mounting insulator (large) nut
Right mounting insulator (small) nut
Right mounting bracket to engine nuts and bolts
Transmission mount insulator nut
Transmission insulator bracket to side member bolt
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
Heat protector
Water pipe bracket bolts

50 ~ 53
28~32 + (60°~64°)
120 ~ 130
120 ~ 130
4 ~ 6
15 ~ 20
12 ~ 15

500 ~ 530
280~320 + (60°~64°)
1200 ~ 1300
1200 ~ 1300
40 ~ 60
150 ~ 200
120 ~ 150

36 ~ 39
20.6~23.6 + (60°~64°)
88 ~ 95
88 ~ 95
3 ~ 4
11 ~15
9 ~ 11
Cooling system
Alternator support bolt and nut
Alternator lock bolt
Alternator brance mounting bolt
Coolant pump pulley bolts
Coolant pump bolts
Coolant temperature sensor
Coolant inlet fitting nuts
Thermostat housing bolts and nuts

20 ~ 25
12 ~ 15
20 ~ 27
8 ~ 10
20 ~ 27
20 ~ 40
15 ~ 20
15 ~ 20

200 ~ 250
120 ~ 150
200 ~ 270
80 ~ 100
200 ~ 270
200 ~ 400
150 ~ 200
150 ~ 200

14 ~ 18
9 ~ 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 stay 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 bracket bolts
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
17 ~ 22
50 ~ 60
50 ~ 60
30 ~ 40
30 ~ 40
40 ~ 60
10 ~ 15

80 ~ 100
40 ~ 60
160 ~ 230
180 ~ 250
150 ~ 200
430 ~ 550
170 ~ 220
500 ~ 600
500 ~ 600
300 ~ 400
300 ~ 400
400 ~ 600
100 ~ 150

6 ~ 7
3 ~ 4
12 ~ 17
13 ~ 18
11 ~ 14
32 ~ 40
12.5 ~ 16
36 ~ 43
36 ~ 43
22 ~ 29
22 ~ 29
29 ~ 43
7 ~ 11
Cylinder head
Cylinder head bolts - M10
Cylinder head bolts - M12
Intake manifold nuts
Exhaust manifold nuts
Cylinder head cover bolts
Camshaft bearing cap bolts
Oil control valve bolt
OCV Filter
CVVT unit 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

160 ~ 170
100 ~ 120
22.6 ~ 28.4
8 ~ 10
20 ~ 27
43 ~ 55

1600 ~ 1700
1000 ~ 1200
230 ~ 290
80 ~ 100
200 ~ 270
430 ~ 550

120 ~ 125
74 ~ 89
16.6 ~ 21.0
6 ~ 7
14 ~ 20
31 ~ 40

M/T : Manual Transmission
A/T : Automatic Transmission
COMPRESSION
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1.
Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2.
Remove ignition coils. (See EE group - ignition)
3.
Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.
4.
Check cylinder compression pressure.
A.
Insert a compression gauge into the spark plug hole.

B.
Fully open the throttle.
C.
While cranking the engine, measure the compression pressure.
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
D.
Repeat steps (a) through (c) for each cylinder.
This measurement must be done in as short a time as possible.

Compression pressure :
1,420kPa (14.5kgf/cm², 206psi)
Minimum pressure :
1,270kPa (13kgf/cm², 184psi)
Difference between each cylinder :
100kPa (1.0kgf/cm², 15psi) or less

E.
If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5.
Reinstall spark plugs.
6.
Install ignition coils. (See EE group - ignition)
Timing belt tension adjustment
1.
Remove the engine cover(A).

2.
Remove RH front wheel.
3.
Remove the 4bolts(B) and timing belt upper cover(A).

4.
Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.

5.
Temperarily loosen tensioner pulley(A) by center bolt.

6.
Timing belt tension adjusting.
(1)
Rotate crankshaft in regular direction (clock wise view from front) through angle equivalent to two teeth (18°) of camshaft sprocket(A).

(2)
Give tension to timing belt rotating tensioner in arrow direction tool and set timing belt not to give slack to tension side.

(3)
Tightening tensioner bolt.

Tightening torque
Tensioner bolt
22.6 ~ 28.4Nm (230 ~ 290kgf.cm, 16.6 ~ 21.0lbf.ft)

(4)
Recheck the belt tension, When the tension side of timing belt is pushed horizontally with a moderate force [approx. 2kg (20N, 5lb)], the timing belt cog end sags 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(A) with 4bolts(B).

Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7lbf.ft)

9.
Install RH front wheel.
10.
Install engine cover(A).

VALVE CLEARANCE INSPECTION AND ADJUSTMENT
MLA (MECHANICAL LASH ADJUSTER)
Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder head is installed on the cylinder block.
1.
Remove the engine cover. (See page EM - 8)
2.
Remove the upper timing belt cover. (See page EM - 9)
A.
Loosen the upper timing cover bolts and then remove the cover.
3.
Remove the cylinder head cover.
A.
Disconnect the spark plug cables and do not pull on the spark plug by force.
Pulling on or bending the cables may damage the connductor inside.
B.
Disconnect the P.C.V hose(A) and the breather hose(B) from the cylinder head cover.

C.
Disconnect the accelerater cable(A) from the cylinder head cover.

D.
Loosen the cylinder head cover bolts(B) and then remove the cover(A) and gasket.

4.
Set No.1 cylinder to TDC/compression.
A.
Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing belt cover.

B.
Check that the hole of the camshaft timing pulley(A) is aligned with the timing mark of the bearing cap.
If not, turn the crankshaft one revolution (360°)

5.
Inspect the valve clearance.
A.
Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

•Using a thickness gauge, measure the clearance between the tappet shim and the base circle of camshaft.
•Record the out-of-specification valve clearance measurements. They will be used later to determine the required replaement adjusing shim.

Valve clearance
SpecificationEngine coolant temperature : 20°C [68°F]Intake : 0.20mm (0.0079in.)Exhaust : 0.28mm (0.0110in.)
LimitIntake : 0.12 ~ 0.28mm (0.0047 ~ 0.0110in.)Exhaust : 0.20 ~ 0.38mm (0.0079 ~ 0.0150in.)

B.
Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the lower timing belt cover.
C.
Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance. (See procedure in step (6))

6.
Adjust the intake and exhaust valve clearance.
A.
Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve is upward.
B.
Using the SST(09220-2D000), press down the valve lifter and place the stopper between the camshaft and valve lifter and remove the special tool.

C.
Remove the adjusting shim with a small screw driver(A) and magnet(B).

D.
Measure the thickness of the removed shim using a micrometer.

E.
Calculate the thickness of a new shim so that the valve clearance comes within the specificified value.

Valve clearance (Engine coolant temperature : 20°C)
T : Thickness of removed shim
A : Measured valve clearance
N : Thickness of new shim
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A-0.28mm (0.0110in.)]

F.
Select a new shim with a thickness as close as possible to the caculated value. [Refer to the Adjusting shim selection chart]
Shims are available in 20size increments of 0.04mm (0.0016in.) from 2.00mm (0.079in.) to 2.76mm (0.1087in.)
G.
Place a new adjusting shim on the valve lifter.
H.
Using the SST(09220-2D000), press down the valve lifter and remove the stopper.
I.
Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C)
[Specification]
Intake : 0.20mm (0.0079in.)
Exhaust : 0.28mm (0.0110in.)
[Limit] (After adjusting valve clearance)
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)
Exhaust : 0.25 ~ 0.31mm (0.0098 ~ 0.0122in.)