2005 Hyundai Elantra GT

2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

2005 ENGINE

Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

GENERAL
SPECIFICATIONS

ENGINE MECHANICAL SYSTEM SPECIFICATIONS

ENGINE MECHANICAL SYSTEM SPECIFICATION

Description Specifications Limit
General
Type In-line, Double Overhead
Camshaft
Number of cylinder 4
Bore 82 mm (3.228 in)
Stroke 93.5 mm (3.681 in.)
Total displacement 1975 cc (120.52 cu.in.)
Compression ratio 10.1
Firing order 1-3-4-2
Valve timing (W/O - CVVT)
Intake valve
Opens (BTDC) 9°
Closes (ABDC) 43°
Exhaust valve
Opens (BBDC) 50°
Closes (ATDC) 6°
Valve timing (W/CVVT)
Intake valve
Opens (ATDC) 11°
Closes (ABDC) 59°
Exhaust
Opens (BBDC) 42°
Closes (ATDC) 6°
Valve
Valve length
Intake 114.34 mm (4.5016 in.)
Exhaust 116.8 mm (4.598 in.)
Stem O.D.
Intake 5.965 ~ 5.98 mm (0.2348 ~ 0.2354
in.)
Exhaust 5.950 ~ 5.965 mm (0.2343 ~
0.2348 in.)

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Face angle thickness of valve

head (Margin)
Intake 1.15 mm (0.0452 in.) 0.8 mm (0.031 in.)
Exhaust 1.35 mm (0.0531 in.) 1.0 mm (0.039 in.)
Valve stem to valve guide
clearance
Intake 0.02 ~ 0.05 mm (0.0008 ~ 0.0019 0.10 mm (0.0039 in.)
in.)
Exhaust 0.035 ~ 0.065 mm (0.0014 ~ 0.13 mm (0.0051 in.)
0.0026 in.)
Valve guide
Installed Dimension O.D.
Intake 46 mm (1.811 in.)
Exhaust 54.5 mm (2.146 in.)
Service Oversize 0.05, 0.25, 0.50 mm (0.002, 0.010,
0.020 in.)
Valve seat
Width of seat contact
Intake 1.1 ~ 1.5 mm (0.043 ~ 0.059in.)
Exhaust 1.3 ~ 1.7 mm (0.051 ~ 0.066in.)
Seat angle 45°
Oversize 0.3, 0.6 mm (0.012, 0.024in.)
oversize
Valve spring
Free length 48.86 mm (1.9236in.)
Load 18.3 kg/39 mm (40.3lb/1.535in.)
Installed height 39 mm (1.5354in.)
Squareness 1.5° or less
Valve clearance
Cold (20°C [68°F])
Intake 0.20 mm (0.0079in.) 0.12 ~ 0.28 mm (0.0047 ~
0.0110in.)
Exhaust 0.28 mm (0.0110 in,) 0.20 ~ 0.38 mm (0.0079 ~
0.0150in.)
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012in.) 0.06 mm (0.0024in.)
Flatness of manifold mounting Max. 0.15 mm (0.0059in.) 0.03 mm (0.0012in.)
surface
Oversize rework dimensions of
valve seat hole
Intake
0.3 mm (0.012in.) O.S. 33.300 ~ 33.325 mm (1.3110 ~
1.3120in.)
0.6 mm (0.024in.) O.S. 33.600 ~ 33.625 mm (1.3228 ~

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

1.3238in.)
Exhaust
0.3 mm (0.012in.) O.S. 28.800 ~ 28.821 mm (1.1338 ~
1.1346in.)
0.6 mm (0.024in.) O.S. 29.100 ~ 29.121 mm (1.1456 ~
1.1465in.)
Oversize rework dimensions of
valve guide hole (both intake and
exhaust)
0.05 mm (0.002in.) O.S 11.05 ~ 11.068 mm (0.435 ~
0.4357in.)
0.25 mm (0.010in.) O.S 11.25 ~ 11.268 mm (0.443 ~
0.4436in.)
0.50 mm (0.020in.) O.S 11.50 ~ 11.518 mm (0.453 ~
0.4535in.)
Cylinder block
Cylinder bore 82.00 ~ 82.03 mm (3.2283 ~
3.2295in.)
Out-of-round and taper of cylinder Less than 0.01 mm (0.0004in.)
bore
Clearance with piston (To set 0.02 ~ 0.04 mm (0.0008 ~
limits to new parts) 0.0016in.)
Piston
O.D (To set limits to new parts) 81.97 ~ 82.00 mm (3.2271 ~
3.2283in.)
Service oversize 0.25, 0.50 mm (0.010, 0.020in.)
oversize
Piston ring
Side clearance
No. 1 0.04 ~ 0.08 mm (0.0015 ~ 0.0031 0.1 mm (0.004in.)
in.)
No. 2 0.03 ~ 0.07 mm (0.0012 ~
0.0027in.)
End gap
No. 1 0.23 ~ 0.38 mm (0.0090 ~ 1 mm (0.039in.)
0.0149in.)
No. 2 0.33 ~ 0.48 mm (0.0130 ~ 1 mm (0.039in.)
0.0189in.)
Oil ring side rail 0.20 ~ 0.60 mm (0.0078 ~ 1 mm (0.039in.)
0.0236in.)
Service oversize 0.25, 0.50 mm
(0.010, 0.020in.) oversize
Connecting rod
Bend 0.05 mm (0.0020in.) or less
Twist 0.1 mm (0.004in.) or less

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Connecting rod big end to 0.100 ~ 0.250 mm (0.0039 ~ 0.4 mm (0.0157in.)

crankshaft side clearance 0.010in.)
Connecting rod bearing
Oil clearance (To seat limits to 0.024 ~ 0.044 mm (0.0009 ~
new parts) 0.0017in.)
Undersize 0.25, 0.50, 0.75 mm (0.01, 0.02,
0.03in.)
Camshaft (W/O - CVVT)
Cam lobe height
Intake 44.820 mm (1.7646in.) 44.720 mm (1.7606in.)
Exhaust 44.720 mm (1.7606in.) 44.620 mm (1.7567in.)
Camshaft (W/CVVT)
Cam height
Intake 44.618 mm (1.7566in.) 44.518 mm (1.7527in.)
Exhaust 44.518 mm (1.7527in.) 44.418 mm (1.7487in.)
Journal O.D. 28 mm (1.1023in.)
Bearing oil clearance 0.02 ~ 0.061 mm (0.0008 ~ 0.1 mm (0.0039in.)
0.0024in.)
End play 0.1 ~ 0.2 mm (0.004 ~ 0.008in.)
Crankshaft
Pin O.D. 45 mm (1.77in.)
Journal O.D. 57 mm (2.244in.)
Bend 0.03 mm (0.0012in.) or less
Out-of-round, taper of journal and 0.01 mm (0.0004in.) or less 0.030 mm (0.0012in.)
pin
End play 0.06 ~ 0.260 mm (0.0023 ~
0.010in.)
Undersize rework dimension of
pin
0.25 mm (0.010in.) 44.725 ~ 44.740 mm (1.7608 ~
1.7614in.)
0.50 mm (0.020in.) 44.475 ~ 44.490 mm (1.7509 ~
1.7516in.)
0.75 mm (0.030in.) 44.225 ~ 44.240 mm (1.7411 ~
1.7417in.)
Undersize rework dimension of
journal
0.25 mm (0.010in.) 56.727 ~ 56.742 mm (2.2333 ~
2.2339in.)
0.50 mm (0.020in.) 56.477 ~ 56.492 mm (2.2235 ~
2.2240in.)
0.75 mm (0.030in.) 56.227 ~ 56.242 mm (2.2136 ~
2.2142in.)
Crankshaft bearing

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Oil clearance 0.028 ~ 0.046 mm (0.0011 ~

0.0018in.)
Flywheel
Runout 0.1 mm (0.0039in.) 0.13 mm (0.0051 in.)
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 83 ~ 110kpa (12 ~ 16psi, 0.83 ~
1.1 kg/cm2 )
Vacuum valve opening pressure -7kpa (-100psi, -0.07kg/cm2 ) or
less
Thermostat
Type Wax pellet type with jiggle valve
Valve opening temperature 82°C (177°F)
Full-opening temperature 95°C (201°F)
Coolant pump Centrifugal type impeller
Drive belt
Type V-ribbed belt
Engine coolant temperature
sensor
Type Heat-sensitive thermistor type
Resistance 2.31 ~ 2.59Kohms at 20°C (68°F)
Oil pump
Clearance between outer 0.120 ~ 0.185 mm (0.0049 ~
0.0073in.)
circumference and front case.
Front case tip clearance 0.025 ~ 0.069 mm (0.0009 ~
0.0027in.)
Side clearance
Inner gear 0.04 ~ 0.085 mm (0.0016 ~
0.0033in.)
Outer gear 0.04 ~ 0.09 mm (0.0016 ~
0.0035in.)
Engine oil pressure at 1,500RPM 245KPa (2.5kg/cm2 , 35.5psi)
[Oil temperature is 90 to 110°C
194 to 230°F)]
Relief spring
Free height 43.8 mm (1.725in.)
Load 3.7kg at 40.1 mm

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

(3.15lb/1.578in.)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers

SERVICE STANDARDS

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

TIGHTENING TORQUE

TIGHTENING TORQUE
Item Nm kgf.cm lbf.ft
Cylinder Block
Front engine support 35 ~ 50 350 ~ 500 25 ~ 37
bracket bolt and nut
Front roll stopper bracket 70 ~ 90 700 ~ 900 51 ~ 65
bolt
Rear roll stopper bracket 70 ~ 90 700 ~ 900 51 ~ 65
bolt
Rear engine stopper 35 ~ 50 350 ~ 500 25 ~ 37
bracket bolt
Engine Mounting
Right mounting insulator 90 ~ 110 900 ~ 1100 65 ~ 80
(large) nut
Right mounting insulator 45 ~ 60 450 ~ 600 33 ~ 44
(small) nut
Right mounting bracket 50 ~ 65 500 ~ 650 36 ~ 48
to engine nuts and bolts
Transmission mount 90 ~ 110 900 ~ 1100 65 ~ 80
insulator nut
Transmission insulator 40 ~ 50 400 ~ 500 30 ~ 36
bracket to side member
bolt
Rear roll stopper 50 ~ 65 500 ~ 650 36 ~ 48
insulator nut
Rear roll stopper bracket 40 ~ 50 400 ~ 500 30 ~ 36
to center member bolts

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Front roll stopper 50 ~ 65 500 ~ 650 36 ~ 48

insulator nut
Front roll stopper bracket 40 ~ 50 400 ~ 500 30 ~ 36
to center member bolts.
Main Moving
Connecting rod cap nut 50 ~ 53 500 ~ 530 36 ~ 39
Crankshaft bearing cap 27~33 + (60°~65°) 270~330 + (60°~65°) 20~24 + (60°~65°)
bolt
Fly wheel M/T bolt 120 ~ 130 1200 ~ 1300 88 ~ 95
Drive plate A/T bolt 120 ~ 130 1200 ~ 1300 88 ~ 95
Engine cover 4~6 40 ~ 60 3~4
Heat protector 15 ~ 20 150 ~ 200 11 ~ 15
Water pipe bracket bolts 12 ~ 15 120 ~ 150 9 ~ 11
Cooling system
Alternator support bolt 20 ~ 25 200 ~ 250 14 ~ 18
and nut
Alternator lock bolt 12 ~ 15 120 ~ 150 9 ~ 11
Alternator brace 20 ~ 27 200 ~ 270 15 ~ 20
mounting bolt
Coolant pump pulley 8 ~ 10 80 ~ 100 6~7
bolts
Coolant pump bolts 20 ~ 27 200 ~ 270 14 ~ 19
Coolant temperature 20 ~ 40 200 ~ 400 15 ~ 30
sensor
Coolant inlet fitting nuts 15 ~ 20 150 ~ 200 11 ~ 14
Thermostat housing bolts 15 ~ 20 150 ~ 200 11 ~ 14
and nuts
Lubrication system
Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Oil pan bolts 10 ~ 12 100 ~ 120 7~9
Oil pan drain plug 40 ~ 45 400 ~ 450 30 ~ 33
Oil screen bolts 15 ~ 22 150 ~ 220 11 ~ 16
Oil pressure switch 13 ~ 15 130 ~ 150 9.7 ~ 11
Intake and Exhaust
system
Air cleaner body 8~ 10 80 ~ 100 6~7
mounting bolts
Resonator mounting bolts 4~6 40 ~ 60 3~4
Intake manifold to 16 ~ 23 160 ~ 230 12 ~ 17
cylinder head nuts and
bolts
Intake manifold stay to 18 ~ 25 180 ~ 250 13 ~ 18
cylinder block bolts

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Throttle body to surge 15 ~ 20 150 ~ 200 11 ~ 14

tank nuts
Exhaust manifold to 43 ~ 55 430 ~ 550 32 ~ 40
cylinder head nuts
Exhaust manifold cover 15 ~ 20 150 ~ 200 11 ~ 14
to exhaust
manifold bolts
Oxygen sensor to front 50 ~ 60 500 ~ 600 36 ~ 43
muffler
Oxygen sensor to exhaust 50 ~ 60 500 ~ 600 36 ~ 43
manifold
Front exhaust pipe to 30 ~ 40 300 ~ 400 22 ~ 29
exhaust manifold nuts
Front exhaust pipe 30 ~ 40 300 ~ 400 22 ~ 29
bracket bolts
Front exhaust pipe to 40 ~ 60 400 ~ 600 29 ~ 43
catalytic converter bolts
Main muffler hanger 10 ~ 15 100 ~ 150 7 ~ 11
support bracket bolts
Cylinder head
Cylinder head bolts - 25 + (60°~65°) + (60° 250 + (60°~65°) + (60° 18 + (60°~65°) + (60°
M10 ~65°) ~65°) ~65°)
Cylinder head bolts - 30 + (60°~65°) + (60° 300 + (60°~65°) + (60° 22 + (60°~65°) + (60°
M12 ~65°) ~65°) ~65°)
Intake manifold nuts 18 ~ 25 180 ~ 250 13 ~ 18
Exhaust manifold nuts 43 ~ 55 430 ~ 550 32 ~ 41
Cylinder head cover bolts 8 ~ 10 80 ~ 100 6~7
Camshaft bearing cap 14 ~ 15 140 ~ 150 10 ~ 11
bolts
Oil control valve bolt 10 ~ 12 100 ~ 120 7.3 ~ 8.8
OCV Filter 41 ~ 51 410 ~ 510 30 ~ 37.6
CVVT unit to exhaust 66 ~ 78 660 ~ 780 48.7 ~ 57.5
camshaft bolt
Rear plate bolts 8 ~ 10 80 ~ 100 6~7
Timing Belt
Crankshaft pulley bolt 170 ~ 180 1700 ~ 1800 125 ~ 133
Camshaft sprocket bolt 100 ~ 120 1000 ~ 1200 74 ~ 89
Timing belt tensioner 43 ~ 550 430 ~ 550 31 ~ 40
bolts
Timing belt cover bolts 8 ~ 10 80 ~ 100 6~7
Front case bolts 20 ~ 27 200 ~ 270 14 ~ 20
Timing belt idler bolt 43 ~ 55 430 ~ 550 31 ~ 40
M/T: Manual Transmission

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

A/T: Automatic Transmission

COMPRESSION

NOTE: 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 IGNITION COIL )

3. Remove spark plugs.

Using a 16 mm plug wrench, remove the 4 spark plugs.

4. Check cylinder compression pressure.

a. Insert a compression gauge into the spark plug hole.

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 1: Inserting Compression Gauge Into Spark Plug Hole

Courtesy of HYUNDAI MOTOR CO.

b. Fully open the throttle.

c. While cranking the engine, measure the compression pressure.

NOTE: Always use a fully charged battery to obtain engine speed of 250 rpm
or more.

d. Repeat steps (a) through (c) for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

Compression pressure :

1,500kPa (15.3kgf/cm2 , 218psi)

Minimum pressure :

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

1,000kPa (10.2kgf/cm2 , 145psi)

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 IGNITION COIL )

TIMING BELT TENSION ADJUSTMENT

1. Remove the engine cover (A).

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 2: Locating Engine Cover

Courtesy of HYUNDAI MOTOR CO.

2. Remove RH front wheel.

3. Remove the 4 bolts (B) and timing belt upper cover (A).

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 3: Removing Bolts

Courtesy of HYUNDAI MOTOR CO.

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

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 4: Identifying Crankshaft Alignment Mark

Courtesy of HYUNDAI MOTOR CO.

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

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 5: Loosening Tensioner Pulley

Courtesy of HYUNDAI MOTOR CO.

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).

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 6: Rotating Crankshaft

Courtesy of HYUNDAI MOTOR CO.

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 :

43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~ 40lbf.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 segs in approx. 4 ~ 6 mm (0.16 ~

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

0.24 in.)

Fig. 7: Checking Timing Belt Tension

Courtesy of HYUNDAI MOTOR CO.

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 4 bolts (B).

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 2005 Hyundai Elantra GT
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Fig. 8: Installing Timing Belt Upper Cover

Courtesy of HYUNDAI MOTOR CO.

9. Install RH front wheel.

10. Install engine cover (A) with 5 bolts.

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 9: Installing Engine Cover

Courtesy of HYUNDAI MOTOR CO.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

MLA (MECHANICAL LASH ADJUSTER)

NOTE: 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 (A).

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 10: Removing Engine Cover

Courtesy of HYUNDAI MOTOR CO.

2. Remove the upper timing belt cover (A).

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 11: Removing Upper Timing Belt Cover

Courtesy of HYUNDAI MOTOR CO.

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.

NOTE: Pulling on or bending the cables may damage the conductor inside.

b. Disconnect the PCV hose (A) and the breather hose (B) from the cylinder head cover.

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Fig. 12: Disconnecting PCV Hose

Courtesy of HYUNDAI MOTOR CO.

c. Disconnect the accelerator cable (A) from the cylinder head cover.

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 13: Locating Accelerator Cable

Courtesy of HYUNDAI MOTOR CO.

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

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 14: Removing Cylinder Head Bolts

Courtesy of HYUNDAI MOTOR CO.

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.

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 15: Identifying Crankshaft Pulley Alignment Mark

Courtesy of HYUNDAI MOTOR CO.

b. Check that the hole of the camshaft timing pulley (A) is aligned with the timing mark of the bearing
cap.

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

If not, turn the crankshaft one revolution (360°)

Fig. 16: Identifying Timing Mark

Courtesy of HYUNDAI MOTOR CO.

5. Inspect the valve clearance

a. Check only the valve indicated as shown in Fig. 17. [No. 1 cylinder: TDC/Compression] measure
the valve clearance

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 17: Inspecting Valve Clearance

Courtesy of HYUNDAI MOTOR CO.

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 replacement adjusting shim.

Valve clearance

Specification

Engine coolant temperature : 20°C (68°F)

Intake : 0.20 mm (0.0079in.)

Exhaust : 0.28 mm (0.0110in.)

Limit

Intake : 0.12 ~ 0.28 mm (0.0047 ~ 0.0110in.)

Exhaust: 0.20 ~ 0.38 mm (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.

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

c. Check only valves indicated as shown in Fig. 18. [NO. 4 cylinder: TDC/compression]. Measure the
valve clearance. (See procedure in step 6.

Fig. 18: Turning Crankshaft Pulley One Revolution

Courtesy of HYUNDAI MOTOR CO.

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.

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 2005 Hyundai Elantra GT
2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 19: Pressing Down Valve Lifter Using SST

Courtesy of HYUNDAI MOTOR CO.

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

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Fig. 20: Removing Adjusting Shim Using Screw Driver

Courtesy of HYUNDAI MOTOR CO.

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

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Fig. 21: Measuring Thickness Of Removed Shim Using Micrometer

Courtesy of HYUNDAI MOTOR CO.

e. Calculate the thickness of a new shim so that the valve clearance comes within the specified 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 - 0.20 mm(0.0079in.)]

Exhaust: N = T + [A - 0.28 mm (0.0110in.)]

f. Select a new shim with a thickness as close as possible to the calculated value. [Refer to the
Adjusting shim selection chart]

NOTE: Shims are available in 20size increments of 0.04 mm (0.0016in.) from

2.00 mm (0.079in.) to 2.76 mm (0.1087in.)

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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 : 0.20 mm (0.0079 in.)

Exhaust : 0.28 mm (0.0110 in.)

[Limit] (After adjusting valve clearance)

Intake : 0.17 ~ 0.23 mm (0.0067 ~ 0.0091 in.)

Exhaust: 0.25 ~ 0.31 mm (0.0098 ~ 0.0122 in.)

Fig. 22: Adjusting Shim Selection Chart (Intake)

Courtesy of HYUNDAI MOTOR CO.

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Fig. 23: Adjusting Shim Selection Chart (Exhaust)

Courtesy of HYUNDAI MOTOR CO.

TROUBLESHOOTING

TROUBLESHOOTING SYMPTOM
Symptom Suspect area Remedy
Engine misfire with abnormal Loose or improperly installed engine Repair or replace the flywheel
internal lower engine noises. flywheel. as required.
Worn piston rings (Oil consumption Inspect the cylinder for a loss of
may or may not cause the engine to compression. Repair or replace
misfire.) as required.
Worn crankshaft thrust bearings. Replace the crankshaft and
bearings as required.
Engine misfire with abnormal Stuck valves (Carbon buildup on the Repair or replace as required.
valve train noise. valve stem can cause the valve not to
close properly.)
Excessive worn or mis-aligned timing Replace the timing chain and
chain sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve

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lifters.
Engine misfire with coolant Faulty cylinder head gasket Inspect the cylinder head
consumption. and/or cranking or other damage and engine block for
to the cylinder head and engine damage to the coolant
block cooling system. passages and/or a faulty
Coolant consumption may or head gasket.
may not cause the engine to Repair or replace as
overheat. required.
Engine misfire with excessive Worn valves, valve guides and/or Repair or replace as required.
oil consumption valve stem oil seals.
Worn piston rings. Inspect the cylinder for a
(Oil consumption may or may not loss of compression.
cause the engine to misfire)
Repair or replace as
required.
Engine noise on start-up, but Incorrect oil viscosity Drain the oil.
only lasting a few seconds.
Install the correct
viscosity oil.
Worn crankshaft thrust bearing Inspect the thrust bearing
and crankshaft.
Repair or replace as
required.
Upper engine noise, regardless Low oil pressure Repair or replace as required.
of engine speed. Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain Replace the timing chain and
and/or damaged sprocket teeth. sprockets.
Worn timing chain tensioner, if Replace the timing chain
applicable. tensioner as required.
Worn camshaft lobes. Inspect the camshaft
lobes.
Replace the timing
camshaft and valve lifters
as required.
Worn valve guides or valve stems. Inspect the valves and valve
guides, then repair as required.
Stuck valves. (Carbon on the valve Inspect the valves and valve
stem or valve seat may cause the valve guides, then repair as required.
to stay open.)
Lower engine noise, regardless Low oil pressure. Repair or replace damaged
of engine speed. components as required.
Loose or damaged flywheel. Repair or replace the flywheel.
Damaged oil pan, contacting the oil Inspect the oil pan.

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pump screen. Inspect the oil pump

screen.
Repair or replace as
required.
Oil pump screen loose, damaged or Inspect the oil pump
restricted. screen.
Repair or replace as
required.
Excessive piston-to-cylinder bore Inspect the piston and
clearance. cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance Inspect the piston, piston
pin and the connecting
rod.
Repair or replace as
required.
Excessive connecting rod bearing Inspect the following
clearance components and repair as
required.

The connecting rod

bearings.
The connecting rods.
The crankshaft.
The crankshaft journal.
Excessive crankshaft bearing clearance Inspect the following
components, and repair as
required :

The crankshaft bearing.

The crankshaft journals.
Incorrect piston, piston pin and Verify the piston pins and
connecting rod installation connecting rods are
installed correctly.
Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Excessive connecting rod bearing Inspect the following
clearance components and repair as
required :

The connecting rod

bearings.

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The connecting rods.

The crankshaft
Excessive crankshaft bearing clearance Inspect the following
components, and repair as
required :

The crankshaft bearings.

The crankshaft journals.
The cylinder block
crankshaft bearing bore.
Engine will not crank-crankshaft Hydraulically locked cylinder 1. Remove spark plugs and
will not rotate check for fluid.
Coolant/antifreeze in cylinder.
2. Inspect for broken head
Oil in cylinder. gasket.
Fuel in cylinder 3. Inspect for cracked engine
black or cylinder head.
4. Inspect for a sticking fuel
injector and/or leaking
fuel regulator.
Broken timing chain and/or timing 1. Inspect timing chain and
chain gears. gears.
2. Repair as required.
Material cylinder 1. Inspect cylinder for
damaged components
Broken valve and/or foreign materials.
Piston material 2. Repair or replace as
Foreign material required
Seized crankshaft or connecting rod 1. Inspect crankshaft and
bearings. connecting rod bearing.
2. Repair as required.
Bent or broken connecting rod. 1. Inspect connecting rods.
2. Repair as required.
Broken crankshaft 1. Inspect crankshaft.
2. Repair as required.

SPECIAL TOOLS

ENGINE MECHANICAL SYSTEM SPECIAL TOOLS

Tool (Number and name) Illustration Use
Crankshaft front oil seal Installation of the front oil seal
installer (09214-33000)

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Valve clearance adjust tool Removal and installation of the

set (09220-2D000) tappet shim

Camshaft oil seal installer Installation of the camshaft oil

(09221-21000) seal

Valve guide installer (09221- Remove and installation of the

3F100 A/B) valve guide

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Valve stem oil seal installer Installation of the valve stem

(09222-22001) oil seal

Valve spring compressor & Removal and installation of the

adaptor (09222-28000, intake or exhaust valve
09222-28100)

Crankshaft rear oil seal 1. Installation of the engine

installer (09231-21000) rear oil seal

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2. Installation of the
crankshaft rear oil seal

TIMING SYSTEM
TIMING BELT

COMPONENT

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Fig. 24: Identifying Timing Belt Components With Torque Specifications

Courtesy of HYUNDAI MOTOR CO.

REMOVAL

Engine removal is not required for this procedure.

1. Remove the engine cover (A).

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Fig. 25: Removing Engine Cover

Courtesy of HYUNDAI MOTOR CO.

2. Remove RH front wheel.

3. Remove 2 bolts (B) and RH side cover (A).

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Fig. 26: Removing RH Side Cover

Courtesy of HYUNDAI MOTOR CO.

4. Remove the engine mount bracket.

1. Set the jack to the engine oil pan.

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Fig. 27: Setting Jack To Engine Oil Pan

Courtesy of HYUNDAI MOTOR CO.

NOTE: Place wooden block between the jack and engine oil pan.

2. Remove the bolt (B), 3 nuts (C) and engine mount bracket (A).

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Fig. 28: Removing Engine Mount Bracket

Courtesy of HYUNDAI MOTOR CO.

3. Remove the bolt (B) and stay plate (A).

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Fig. 29: Removing Bolt And Stay Plate

Courtesy of HYUNDAI MOTOR CO.

5. Temporarily loosen the water pump pulley bolts.

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Fig. 30: Loosening Water Pump Pulley Bolts

Courtesy of HYUNDAI MOTOR CO.

6. Remove alternator belt. (See ALTERNATOR BELT INSPECTION AND ADJUSTMENT )

7. Remove air compressor belt. (See REPLACEMENT )
8. Remove power steering belt. (See REMOVAL )
9. Remove 4 bolts and water pump pulley.
10. Remove the 4 bolts (B) and timing belt upper cover (A).

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Fig. 31: Removing Alternator Belt

Courtesy of HYUNDAI MOTOR CO.

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

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Fig. 32: Turning Crankshaft Pulley

Courtesy of HYUNDAI MOTOR CO.

12. Remove the crankshaft pulley bolt (B) and crankshaft pulley (A).

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Fig. 33: Removing Crankshaft Pulley Bolt

Courtesy of HYUNDAI MOTOR CO.

13. Remove the crankshaft flange (A).

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Fig. 34: Removing Crankshaft Flange

Courtesy of HYUNDAI MOTOR CO.

14. Remove the 5 bolts (B) and timing belt lower cover (A).

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Fig. 35: Removing Timing Belt Lower Cover

Courtesy of HYUNDAI MOTOR CO.

15. Remove the timing belt tensioner (A) and timing belt (B).

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Fig. 36: Removing Timing Belt Tensioner

Courtesy of HYUNDAI MOTOR CO.

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Fig. 37: Removing Timing Belt

Courtesy of HYUNDAI MOTOR CO.

NOTE: If the timing belt is reused, make an arrow indicating the turning direction
to make sure that the belt is reinstalled in the same direction as before.

16. Remove the bolt (B) and timing belt idler (A).

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Fig. 38: Removing Bolt And Timing Belt Idler

Courtesy of HYUNDAI MOTOR CO.

17. Remove the crankshaft sprocket (A).

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Fig. 39: Removing Crankshaft Sprocket

Courtesy of HYUNDAI MOTOR CO.

18. Remove the cylinder head cover.

1. Remove the spark plug cable.
2. Remove the accelerator cable (A) from the cylinder head cover.

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Fig. 40: Removing Accelerator Cable

Courtesy of HYUNDAI MOTOR CO.

3. Remove the PCV (Positive Crankcase Ventilation) hose (A) and breather hose (B).

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Fig. 41: Removing PCV (Positive Crankcase Ventilation)

Courtesy of HYUNDAI MOTOR CO.

4. Remove the 12 bolts (B) and cylinder head cover (A).

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Fig. 42: Removing Cylinder Head Cover

Courtesy of HYUNDAI MOTOR CO.

19. Remove camshaft sprocket.

1. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and remove the
bolt and camshaft sprocket (C).

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Fig. 43: Removing Camshaft Sprocket

Courtesy of HYUNDAI MOTOR CO.

CAUTION: Be careful not to damage the cylinder head and valve lifter with
the wrench.

INSPECTION

SPROCKETS, TENSIONER, IDLER

1. Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear,
cracks, or damage. Replace as necessary.

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2. Inspect the tensioner pulley and the idler pulley for easy and smooth rotation and check for play or noise.
Replace as necessary.

Fig. 44: Inspecting Tensioner Pulley

Courtesy of HYUNDAI MOTOR CO.

3. Replace the pulley if there is a grease leak from its bearing.

TIMING BELT

1. Check the belt for oil or dust deposits.

Replace, if necessary.

Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.

2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of the following
flaws are evident, replace the belt.

NOTE: Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water and
steam.

INSTALLATION

1. Install the camshaft sprocket and tighten the bolt to the specified torque

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1. Temporarily install the camshaft sprocket bolt.

2. Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the
camshaft sprocket (C) bolt.

Tightening torque

Camshaft sprocket bolt

100 ~ 120Nm (1000 ~ 1200kgf.cm, 74 ~ 89lbf.ft)

Fig. 45: Holding Hexagonal Head Wrench Of Camshaft With A Wrench

Courtesy of HYUNDAI MOTOR CO.

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2. Install cylinder head cover.

1. Install cylinder head cover (A) and 12 bolts (B).

Fig. 46: Installing Cylinder Head Cover

Courtesy of HYUNDAI MOTOR CO.

2. Install the PCV hose (A) and breather hose (B).

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Fig. 47: Installing PCV Hose And Breather Hose

Courtesy of HYUNDAI MOTOR CO.

3. Install the accelerator cable (A) from the cylinder head cover.

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Fig. 48: Installing Accelerator Cable

Courtesy of HYUNDAI MOTOR CO.

4. Install the spark plug cable.

3. Install the crankshaft sprocket (A).

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Fig. 49: Installing Crankshaft Sprocket

Courtesy of HYUNDAI MOTOR CO.

4. Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston
placed at top dead center and its compression stroke.

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Fig. 50: Identifying Camshaft Timing Mark

Courtesy of HYUNDAI MOTOR CO.

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Fig. 51: Aligning Crankshaft Timing Mark

Courtesy of HYUNDAI MOTOR CO.

5. Install the idler pulley (A) and tighten the bolt (B) to the specified torque.

Tightening torque

Idler pulley bolt :

43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~ 40lbf.ft)

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Fig. 52: Installing Idler Pulley

Courtesy of HYUNDAI MOTOR CO.

6. Temporarily install the timing belt tensioner (A) with plain washer (B).

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Fig. 53: Installing Timing Belt Tensioner

Courtesy of HYUNDAI MOTOR CO.

7. Belt so as not give slack at each center of shaft. Do as following procedures when installing timing belt.
Crankshaft sprocket (A) --> Idler pulley (B) --> Camshaft sprocket (C) --> timing belt tensioner (D).

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Fig. 54: Installing Timing Belt

Courtesy of HYUNDAI MOTOR CO.

8. Temporarily fasten tensioner pulley by center bolt to add force at belt.

9. Timing belt tension adjusting
1. Rotate crankshaft in regular direction (clock wise view from front) through angle equivalent to two

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teeth (18°) of camshaft sprocket (A).

Fig. 55: Adjusting Timing Belt Tension

Courtesy of HYUNDAI MOTOR CO.

2. Give tension to timing belt by rotating tensioner in arrow direction with tool and set timing belt not
to give slack to tension side
3. Tightening tensioner bolt.

Tightening torque

Tensioner bolt :

43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~ 40lbf.ft)

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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 ~ 6 mm (0.16 ~
0.24 in.)

Fig. 56: Checking Belt Tension

Courtesy of HYUNDAI MOTOR CO.

10. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and
camshaft sprocket timing mark.
11. Install the timing belt lower cover (A) with 5 bolts (B).

Tightening torque

Timing belt cover bolt :

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8 ~ 10Nm (80 ~ 100kg.cm, 6 ~ 7lbf.ft)

Fig. 57: Installing Timing Belt

Courtesy of HYUNDAI MOTOR CO.

12. Install the flange and crankshaft pulley (A).

Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque

Crankshaft pulley bolt :

170 ~ 180Nm (1700 ~ 1800kgf.cm, 125 ~ 133lbf.ft)

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Fig. 58: Installing Flange And Crankshaft Pulley

Courtesy of HYUNDAI MOTOR CO.

13. Install the timing belt upper cover (A) with 4bolts (B).

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Fig. 59: Installing Timing Belt Upper Cover

Courtesy of HYUNDAI MOTOR CO.

14. Install the coolant pump pulley with 4bolts.

15. Install power steering belt, (See INSTALLATION )
16. Install air compressor bolt. (See REPLACEMENT )
17. Install alternator belt. (See ALTERNATOR BELT INSPECTION AND ADJUSTMENT )
18. Install the engine mount bracket
1. Install the stay plate (A) with bolt (B).

Tightening torque

Stay plate bolt :

43 ~ 55Nm (430 ~ 550kgf.cm, 32 ~ 40lbf.ft)

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Fig. 60: Installing Engine Mount Bracket

Courtesy of HYUNDAI MOTOR CO.

2. Install engine mount bracket with 3nuts (C) and bolt (B).

Tightening torque

17 mm nut: 60 ~80Nm (600 ~ 800kgf.cm, 44 ~ 59lbf.ft)

14 mm nut: 50 ~65Nm (500 ~ 650kgf.cm, 37 ~ 48lbf.ft)

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Fig. 61: Installing Engine Mount Bracket

Courtesy of HYUNDAI MOTOR CO.

19. Install RH side cover (A) with 2 bolts (B).

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Fig. 62: Installing RH Side Cover

Courtesy of HYUNDAI MOTOR CO.

20. Install RH front wheel.

21. Install engine cover (A) with 5 bolts.

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Fig. 63: Install Engine Cover Using Bolts

Courtesy of HYUNDAI MOTOR CO.

CYLINDER HEAD ASSEMBLY

COMPONENTS

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Fig. 64: Identifying Cylinder Head Assembly Components With Torque Specifications (1 Of 2)
Courtesy of HYUNDAI MOTOR CO.

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Fig. 65: Identifying Cylinder Head Assembly Components With Torque Specifications (2 Of 2)
Courtesy of HYUNDAI MOTOR CO.

REMOVAL

Engine removal is not required for this procedure.

CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or
damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.

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NOTE: Mark all wiring and hoses to avoid misconnection.

Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
(See a).

1. Disconnect the negative terminal from the battery.

Fig. 66: Disconnecting Negative Terminal From Battery

Courtesy of HYUNDAI MOTOR CO.

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2. Remove the engine cover (A).

Fig. 67: Removing Engine Cover

Courtesy of HYUNDAI MOTOR CO.

3. Drain the engine coolant (See ENGINE COOLANT REFILLING AND BLEEDING). Remove the
radiator cap to speed draining.
4. Remove the intake air hose and air cleaner assembly.
1. Remove the heat shield (A).

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Fig. 68: Removing Heat Shield

Courtesy of HYUNDAI MOTOR CO.

2. Disconnect the AFS connector.

3. Disconnect the breather hose from air cleaner hose.
4. Remove the intake air hose and air cleaner assembly.
5. Remove the upper radiator hose (A) and lower radiator hose (B).

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Fig. 69: Removing Upper Radiator Hose

Courtesy of HYUNDAI MOTOR CO.

6. Remove the heater hoses (A).

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Fig. 70: Removing Heater Hoses

Courtesy of HYUNDAI MOTOR CO.

7. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
1. OCV (Oil control Valve) connector (A).
2. Oil temperature sensor connector (B).
3. ECT (Engine Coolant Temperature) sensor connector (C).
4. Ignition coil connector (D).

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Fig. 71: Removing Engine Wire Harness Connectors

Courtesy of HYUNDAI MOTOR CO.

5. TPS (Throttle Position Sensor) connector (A).

6. ISA (Idle Speed Actuator) connector (B).

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Fig. 72: Identifying Throttle Position Sensor

Courtesy of HYUNDAI MOTOR CO.

7. CMP (Camshaft Position Sensor) connector (A).

8. Four fuel injector connectors (B).
9. Knock sensor connector (C).
10. Disconnect ground cable (D) from the intake manifold.

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Fig. 73: Identifying Camshaft Position Sensor

Courtesy of HYUNDAI MOTOR CO.

11. Front heated oxygen sensor connector (A).

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Fig. 74: Identifying Front Heated Oxygen Sensor Connector

Courtesy of HYUNDAI MOTOR CO.

12. PCSV (Purge Control Solenoid Valve) connector (A).

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Fig. 75: Identifying Purge Control Solenoid Valve

Courtesy of HYUNDAI MOTOR CO.

8. Remove the fuel inlet hose (A) from delivery pipe.

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Fig. 76: Removing Fuel Inlet Hose

Courtesy of HYUNDAI MOTOR CO.

9. Remove the PCSV hose (A).

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Fig. 77: Removing PCSV Hose

Courtesy of HYUNDAI MOTOR CO.

10. Remove the brake booster vacuum hose (A).

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Fig. 78: Removing Brake Booster Vacuum Hose

Courtesy of HYUNDAI MOTOR CO.

11. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
12. Remove the power steering pump. (See REMOVAL ).
13. Remove the power steering pump bracket bolts (A).

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Fig. 79: Removing Power Steering Pump Bracket Bolts

Courtesy of HYUNDAI MOTOR CO.

14. Remove the spark plug cable. (See INSPECT SPARK PLUG AND SPARK PLUG CABLE )
15. Remove the PCV hose. (See VALVE CLEARANCE INSPECTION AND ADJUSTMENT)
16. Remove the cylinder head cover. (See d)
17. Remove the timing belt. (See REMOVAL)
18. Remove the exhaust manifold. (See EXHAUST MANIFOLD)
19. Remove the intake manifold. (See INTAKE AND EXHAUST SYSTEM)
20. Remove the camshaft sprocket. (See SPROCKETS, TENSIONER, IDLER)
21. Remove the timing chain auto tensioner (A).

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Fig. 80: Removing Timing Chain Auto Tensioner

Courtesy of HYUNDAI MOTOR CO.

22. Remove the camshaft bearing caps (A) and camshafts (B).

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Fig. 81: Removing Camshaft Bearing Caps

Courtesy of HYUNDAI MOTOR CO.

23. Remove the OCV (oil control valve) (A).

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Fig. 82: Removing Oil Control Valve

Courtesy of HYUNDAI MOTOR CO.

24. Remove the OCV (oil control valve) filter (A).

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Fig. 83: Removing Oil Control Valve Filter

Courtesy of HYUNDAI MOTOR CO.

25. Remove the cylinder head bolts, then remove the cylinder head.
1. Using 8 mm and 10 mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts,
in several passes, in the sequence shown in Fig. 84. Remove the 10 cylinder head bolts and plate
washers.

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Fig. 84: Identifying Bolt Removing Sequence

Courtesy of HYUNDAI MOTOR CO.

CAUTION: Head warpage or cracking could result from removing bolts in

an incorrect order.

2. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on
wooden blocks on a bench.

CAUTION: Be careful not to damage the contact surfaces of the cylinder

head and cylinder block.

DISASSEMBLY

NOTE: Identify MLA (Mechanical Lash Adjuster), valves, valve springs as they are
removed so that each item can be reinstalled in its original position.

1. Remove MLAs. (A)

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Fig. 85: Locating MLAs

Courtesy of HYUNDAI MOTOR CO.

2. Remove valves.
1. Using SST(09222-28000, 09222-28100), compress the valve spring and remove retainer lock.

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Fig. 86: Compressing Valve Spring Using SST

Courtesy of HYUNDAI MOTOR CO.

2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Remove the using needle-nose pliers, remove the oil seal.
6. Using a magnetic finger, remove the spring seat.

INSPECTION

CYLINDER HEAD

1. Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block
and the manifolds for warpage.

Flatness of cylinder head gasket surface

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Standard : Less than 0.03 mm (0.0012 in.)

Limit : 0.06 mm (0.0024 in.)

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Fig. 87: Measuring Surface Contacting Cylinder Block

Courtesy of HYUNDAI MOTOR CO.

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect valve stems and valve guides.

1. Using a caliper gauge, measure the inside diameter or the valve guide.

Valve guide inside.

Fig. 88: Measuring Inside Diameter Of Valve Guide

Courtesy of HYUNDAI MOTOR CO.

2. Using a micrometer, measure the diameter of the valve stem.

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Fig. 89: Measuring Diameter Of Valve Stem

Courtesy of HYUNDAI MOTOR CO.

3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to-guide clearance

[Standard]

Intake : 0.02 ~ 0.05 mm (0.0008 ~ 0.0020 in.)

Exhaust: 0.035 ~ 0.065 mm (0.0014 ~ 0.0026 in.)

[Limit]

Intake : 0.1 mm (0.0040 in.)

Exhaust: 0.13 mm (0.0051 in.)

If the clearance is greater than maximum, replace the valve and valve guide.

2. Inspect valves.

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1. Check the valve is ground to the correct valve face angle.

2. Check that the surface of the valve for wear. If the valve face is worn, replace the valve.
3. Check the valve head margin thickness. If the margin thickness is less than minimum, replace the
valve.

Margin

[Standard]

Intake : 1.15 mm (0.0453 in.)

Exhaust : 1.35 mm (0.0531 in.)

[Limit]

Intake : 0.8 mm (0.0315 in.)

Exhaust : 1.0 mm (0.040 in.)

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Fig. 90: Identifying Valve Margin

Courtesy of HYUNDAI MOTOR CO.

4. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.

Replace the seat if necessary.

Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then

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recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact
width should be within specifications and centered on the valve face.

4. Inspect valve springs.

1. Using a steel square, measure the out-of-square of the valve spring.
2. Using a vernier calipers, measure the free length of the valve spring.

Valve spring

[Standard]

Free height: 48.86 mm (1.9236 in.)

Load : 18.3kg / 39 mm (40.3lb /1.535 in.)

[Limit]

Free height: -1.0 mm( -0.0394 in.)

Out-of-square : 3°

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Fig. 91: Measuring Free Length Of Valve Spring

Courtesy of HYUNDAI MOTOR CO.

If the free length is not as specified, replace the valve spring.

CAMSHAFT

1. Inspect cam lobes.

Using a micrometer, measure the cam lobe height.

Cam height

W/O CVVT

[Standard value]

Intake : 44.820 mm (1.7646 in.)

Exhaust: 44.720 mm (1.7606 in.)

[Limit]

Intake : 44.720 mm (1.7606 in.)

Exhaust: 44.620 mm (1.7567 in.)

W/CVVT

[Standard value]

Intake : 44.618 mm (1.7566 in.)

Exhaust: 44.518 mm (1.7527 in.)

[Limit]

Intake : 44.518 mm (1.7527 in.)

Exhaust: 44.418 mm (1.7487 in.)

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Fig. 92: Measuring Cam Lobe Height

Courtesy of HYUNDAI MOTOR CO.

If the cam lobe height is less than minimum, replace the camshaft.

2. Inspect camshaft journal clearance.

1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journal.

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Fig. 93: Laying Strip Of Plastigage Across Camshaft Journal

Courtesy of HYUNDAI MOTOR CO.

4. Install the bearing caps. (See 2)

CAUTION: Do not turn the camshaft.

5. Remove the bearing caps.

6. Measure the plastigage at its widest point.

Bearing oil clearance :

[Standard value]: 0.02 ~ 0.061 mm (0.0008 ~ 0.0024 in.)

[Limit] : 0.1 mm (0.0039 in.)

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Fig. 94: Measuring Plastigage At Its Widest Point

Courtesy of HYUNDAI MOTOR CO.

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

7. Completely remove the plastigage.

8. Remove the camshafts.
3. Inspect camshaft end play.
1. Install the camshafts. (See 6).
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

[Standard value]: 0.1 ~ 0.2 mm (0.004 ~ 0.008 in.)

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Fig. 95: Measuring End Play While Moving Camshaft Back And Forth
Courtesy of HYUNDAI MOTOR CO.

If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.

3. Remove the camshafts.

CVVT ASSEMBLY

1. Inspect CVVT assembly.

1. Check that the CVVT assembly will not turn.
2. Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.

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Fig. 96: Inspecting CVVT Assembly

Courtesy of HYUNDAI MOTOR CO.

3. Wind tape around the tip of the air gun and apply air of approx. 100 kpa (1kgf/cm2 , 14 psi) to the
port of the camshaft.

(Perform this order to release the lock pin for the maximum delay angle locking.)

NOTE: When the oil splashes, wipe it off with a shop rag and the likes.

4. Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked
direction in the illustration) with your hand. Depending on the air pressure, the CVVT assembly
will turn to the advance side without applying force by hand. Also, under the condition that the

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pressure can be hardly applied because of the air leakage from the port, there may be the case that
the lock pin could be hardly released.
5. Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly
turn back and forth and check the movable range and that there is no disturbance.

Standard: Movable smoothly in the range about 20°

6. Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

REPLACEMENT

VALVE GUIDE

1. Using the SST(09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.

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Fig. 97: Withdrawing Old Valve Guide Using SST

Courtesy of HYUNDAI MOTOR CO.

2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3. Using the SST(09221-3F100 A/B), press-fit the valve guide. The valve guide must be press-fitted from
the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in
length.

VALVE SPECIFICATION
Over size mm (in.) Size mark Oversize valve guide hole size mm (in.)
0.05 (0.002) 5 11.05 ~ 11.068 (0.4350 ~ 0.4357)
0.25(0.010) 25 11.25 ~ 11.268 (0.4429 ~ 0.4436)
0.50 (0.020) 50 11.50~ 11.518 (0.4528 ~ 0.4535)

Valve guide length

Intake : 46 mm (1.8in.)

Exhaust : 54.5 mm (2.1 5in.)

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Fig. 98: Press-Fitting Valve Guide

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Courtesy of HYUNDAI MOTOR CO.

4. After the valve guide is press-fitted, insert a new valve and check for proper stem-to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as
necessary.

REASSEMBLY

NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply
fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new
ones.

1. Install valves.
1. Install the spring seats.
2. Using SST (09222-22001), push in a new oil seal.

NOTE: Do not reuse old valve stem seals. Incorrect installation of the seal
could result in oil leakage past the valve guides.

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Fig. 99: Installing Valve

Courtesy of HYUNDAI MOTOR CO.

3. Install the valve, valve spring and spring retainer.

NOTE: Place valve springs so that the side coated with enamel faces toward
the valve spring retainer and then installs the retainer.

4. Using the SST (09222-28000, 09222-28100), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve spring compressor.

Fig. 100: Installing Retainer Locks Using SST

Courtesy of HYUNDAI MOTOR CO.

5. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.

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Fig. 101: Taping End Of Each Valve Stem

Courtesy of HYUNDAI MOTOR CO.

2. Install MLAs.

Check that the MLA rotates smoothly by hand.

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Fig. 102: Installing MLAs

Courtesy of HYUNDAI MOTOR CO.

INSTALLATION

NOTE: Thoroughly clean all parts to be assembled.

Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC. (See 4).

1. Install the cylinder head gasket (A) on the cylinder block.

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Fig. 103: Installing Cylinder Head Gasket

Courtesy of HYUNDAI MOTOR CO.

NOTE: Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
1. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2. Using 8 mm and 10 mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate
washers, in several passes, in the sequence shown in Fig. 104.

Tightening torque

M10 :

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25Nm (250kgf.cm, 18lbf.ft) + (60° ~ 65°) + (60° ~ 65°)

M12 :

30Nm (300kgf.cm, 22lbf.ft) + (60° ~ 65°) + (60° ~ 65°)

Fig. 104: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of HYUNDAI MOTOR CO.

4. Install OCV filter (A).

Tightening torque

41 ~ 51 Nm (410 ~ 510kgf.cm, 30 ~ 37.6lbf.ft)

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Fig. 105: Installing OCV Filter

Courtesy of HYUNDAI MOTOR CO.

NOTE: Always use a new OCV filter gasket. Keep clean the OCV filter.

5. Install OCV. (A)

Tightening torque

10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)

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Fig. 106: Installing OCV

Courtesy of HYUNDAI MOTOR CO.

CAUTION: Do not reuse the OCV when dropped.

Keep clean the OCV.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move the
engine with holding the OCV yoke.

6. Install the camshafts.

1. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain
sprocket as shown in Fig. 107.

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Fig. 107: Aligning Camshaft Timing Chain

Courtesy of HYUNDAI MOTOR CO.

2. Install the camshafts (A) and bearing caps (B).

Tightening torque

14 ~ 15Nm (140 ~ 150kgf.cm, 10 ~ 11lbf.ft)

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Fig. 108: Installing Camshafts And Bearing Caps

Courtesy of HYUNDAI MOTOR CO.

3. Install the timing chain auto tensioner (A).

Tightening torque

8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7.4lbf.ft)

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Fig. 109: Installing Timing Chain Auto Tensioner

Courtesy of HYUNDAI MOTOR CO.

4. Remove the auto tensioner stopper pin (B).

7. Check and adjust valve clearance. (See VALVE CLEARANCE INSPECTION AND
ADJUSTMENT).
8. Using the SST (09221-21000), install the camshaft bearing oil seal.

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Fig. 110: Installing Camshaft Bearing Oil Seal Using SST

Courtesy of HYUNDAI MOTOR CO.

9. Install the camshaft sprocket. (See INSTALLATION).

10. Install the timing belt. (See INSTALLATION).
11. Install the cylinder head cover.
1. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B).

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Fig. 111: Installing Cylinder Head Cover Gasket

Courtesy of HYUNDAI MOTOR CO.

NOTE: Before installing the head cover gasket, thoroughly clean the
head cover gasket and the groove.
When installing, make sure the head cover gasket is seated
securely in the corners of the recesses with no gap.

2. Apply liquid gasket to the head cover gasket at the corners of the recess.

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Fig. 112: Applying Liquid Gasket To Head Cover Gasket

Courtesy of HYUNDAI MOTOR CO.

NOTE: Use liquid gasket, loctite No. 5999.

Check that the mating surfaces are clean and dry before
applying liquid gasket
After assembly, wait at least 30 minutes before filling the engine
with oil.

3. Install the cylinder head cover (A) with the 12bolts (B). Uniformly tighten the bolts in several
passes.

Tightening torque

8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~ 7.4 lbf.ft)

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Fig. 113: Installing Cylinder Head Cover

Courtesy of HYUNDAI MOTOR CO.

12. Install the intake manifold. (See INTAKE AND EXHAUST SYSTEM).
13. Install the exhaust manifold. (See EXHAUST MANIFOLD)
14. Install the PCV. (See INSTALLATION)
15. Install the spark plug cable. (See REPLACEMENT )
16. Install the power steering pump bracket bolts (A).

Tightening torque

35 ~ 50Nm (350 ~ 500kgf.cm, 26 ~ 37lbf.ft)

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Fig. 114: Installing Power Steering Pump Bracket Bolts

Courtesy of HYUNDAI MOTOR CO.

17. Install the power steering pump. (See INSTALLATION )

18. Install the accelerator cable.
19. Install the bake booster hose.
20. Install the PCSV hose (A).

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Fig. 115: Installing PCSV Hose

Courtesy of HYUNDAI MOTOR CO.

21. Install the fuel inlet hose (A).

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Fig. 116: Installing Fuel Inlet Hose

Courtesy of HYUNDAI MOTOR CO.

22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake
manifold.
1. PCSV connector (A).

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Fig. 117: Installing Engine Wire Harness Connectors

Courtesy of HYUNDAI MOTOR CO.

2. Front heated oxygen sensor connector (A).

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Fig. 118: Identifying Front Heated Oxygen Sensor Connector

Courtesy of HYUNDAI MOTOR CO.

3. Connect the ground cable to the intake manifold (D).

4. Knock sensor connector (C).
5. Four fuel injector connectors (B).
6. CMP connector (A).

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Fig. 119: Identifying CMP Connector

Courtesy of HYUNDAI MOTOR CO.

7. ISA connector (B).

8. TPS connector (A).

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Fig. 120: Identifying TPS Connector

Courtesy of HYUNDAI MOTOR CO.

9. Ignition coil connector (D).

10. ECT sensor connector (C).
11. Oil temperature sensor connector (B).
12. OCV connector (A).

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Fig. 121: Ignition Coil Connector

Courtesy of HYUNDAI MOTOR CO.

23. Install the heater hoses (A).

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Fig. 122: Installing Heater Hoses

Courtesy of HYUNDAI MOTOR CO.

24. Install the upper radiator hose (A) and lower radiator hose (B).

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Fig. 123: Installing Upper Radiator Hose

Courtesy of HYUNDAI MOTOR CO.

25. Install the intake air hose and air cleaner assembly.
26. Install the engine cover (A).

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Fig. 124: Installing Intake Air Hose

Courtesy of HYUNDAI MOTOR CO.

27. Connect the negative terminal to the battery.

28. Fill with engine coolant.
29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.

ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL

CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.

NOTE: Mark all wiring and hoses to avoid misconnection.

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Inspection the timing belt before removing the cylinder head.

Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
(See a)

1. Disconnect the negative terminal from the battery.

Fig. 125: Disconnecting Negative Terminal From Battery

Courtesy of HYUNDAI MOTOR CO.

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2. Remove the engine cover.

Fig. 126: Removing Engine Cover

Courtesy of HYUNDAI MOTOR CO.

3. Drain the engine coolant (See ENGINE COOLANT REFILLING AND BLEEDING) Remove the
radiator cap to speed draining.
4. Remove the intake air hose and air cleaner assembly.
1. Remove the heat shield (A).

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Fig. 127: Removing Heat Shield

Courtesy of HYUNDAI MOTOR CO.

2. Disconnect the AFS connector.

3. Disconnect the breather hose from air cleaner hose.
4. Remove the intake air hose and air cleaner.
5. Remove the upper radiator hose (A) and lower radiator hose (B).

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Fig. 128: Removing Upper Radiator Hose

Courtesy of HYUNDAI MOTOR CO.

6. Remove the heater hoses (A).

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Fig. 129: Removing Heater Hoses

Courtesy of HYUNDAI MOTOR CO.

7. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the
intake manifold.
1. OCV (Oil Control Valve) connector (A).
2. Oil temperature sensor connector (B).
3. ECT (Engine Coolant Temperature) sensor (C) connector.
4. Ignition coil connector (D).

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Fig. 130: Identifying Ignition Coil Connector

Courtesy of HYUNDAI MOTOR CO.

5. TPS (Throttle Position Sensor) connector (A).

6. ISA (Idle Speed Actuator) connector (B).

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Fig. 131: Identifying Throttle Position Sensor

Courtesy of HYUNDAI MOTOR CO.

7. CMP (Camshaft Position Sensor) connector (A).

8. Four fuel injector connectors (B).
9. Knock sensor connector (C).
10. Disconnect ground cable (D) from the intake manifold.

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Fig. 132: Identifying Camshaft Position Sensor

Courtesy of HYUNDAI MOTOR CO.

11. Front heated oxygen sensor (A) connector.

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Fig. 133: Identifying Front Heated Oxygen Sensor

Courtesy of HYUNDAI MOTOR CO.

12. PCSV (Purge Control Solenoid Valve) (A) connector.

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Fig. 134: Identifying Purge Control Solenoid Valve

Courtesy of HYUNDAI MOTOR CO.

8. Remove the fuel inlet from delivery pipe (A).

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Fig. 135: Removing Fuel Inlet

Courtesy of HYUNDAI MOTOR CO.

9. Remove the PCSV hose (A).

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Fig. 136: Removing PCSV Hose

Courtesy of HYUNDAI MOTOR CO.

10. Remove the brake booster vacuum hose (A).

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Fig. 137: Removing Brake Booster Vacuum Hose

Courtesy of HYUNDAI MOTOR CO.

11. Remove the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
12. Remove the power steering pump, (See page REMOVAL )
13. Disconnect the inhibitor switch and solenoid valve connector (A).

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Fig. 138: Disconnecting Inhibitor Switch

Courtesy of HYUNDAI MOTOR CO.

14. Remove the transaxle range switch connector (A).

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Fig. 139: Removing Transaxle Range Switch Connector

Courtesy of HYUNDAI MOTOR CO.

15. Remove the vehicle speed sensor connector (A).

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Fig. 140: Removing Vehicle Speed Sensor Connector

Courtesy of HYUNDAI MOTOR CO.

16. Remove the control cable transaxle range switch nut (A).

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Fig. 141: Removing Control Cable Transaxle Range Switch Nut

Courtesy of HYUNDAI MOTOR CO.

17. Remove the clip (A) of the control cable.

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Fig. 142: Removing Clip Of Control Cable

Courtesy of HYUNDAI MOTOR CO.

18. Remove the input shaft speed sensor connector (A).

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Fig. 143: Removing Input Shaft Speed Sensor

Courtesy of HYUNDAI MOTOR CO.

19. Remove the output shaft speed sensor connector (A).

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Fig. 144: Removing Output Shaft Speed Sensor Connector

Courtesy of HYUNDAI MOTOR CO.

20. Remove the transaxle earth cable (A).

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Fig. 145: Removing Transaxle Earth Cable

Courtesy of HYUNDAI MOTOR CO.

21. Remove the start motor cable mounting bolt (A).

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Fig. 146: Removing Start Motor Cable Mounting Bolt

Courtesy of HYUNDAI MOTOR CO.

22. Remove the starting motor connector.

23. Remove the alternator connector.
24. Install the SST (09200-38001, 09200-1C000), the engine support fixture and the adapter, on the engine
and transaxle assembly.

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Fig. 147: Removing Alternator Connector

Courtesy of HYUNDAI MOTOR CO.

25. Remove the engine mounting bracket (A).

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Fig. 148: Removing Engine Mounting Bracket

Courtesy of HYUNDAI MOTOR CO.

26. Remove the transaxle mounting bracket (A).

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Fig. 149: Removing Transaxle Mounting Bracket

Courtesy of HYUNDAI MOTOR CO.

27. Remove the front tires.

28. Remove the ABS wheel speed sensor (A).

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Fig. 150: Removing ABS Wheel Speed Sensor

Courtesy of HYUNDAI MOTOR CO.

29. Remove the caliper and hang the caliper assembly (A).

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Fig. 151: Locating Caliper Assembly

Courtesy of HYUNDAI MOTOR CO.

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Fig. 152: Removing Caliper

Courtesy of HYUNDAI MOTOR CO.

30. Remove the knuckle mounting bolts (A).

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Fig. 153: Removing Knuckle Mounting Bolts

Courtesy of HYUNDAI MOTOR CO.

31. Remove the power steering return hose (A) and drain the power steering oil.

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Fig. 154: Removing Power Steering Return Hose

Courtesy of HYUNDAI MOTOR CO.

32. Disconnect the rear oxygen sensor connector (A).

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Fig. 155: Disconnecting Rear Oxygen Sensor Connector

Courtesy of HYUNDAI MOTOR CO.

33. Remove the front muffler (A).

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Fig. 156: Removing Front Muffler

Courtesy of HYUNDAI MOTOR CO.

34. Remove the steering u-joint mounting bolt (A).

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Fig. 157: Removing Steering U-Joint Mounting Bolt

Courtesy of HYUNDAI MOTOR CO.

35. Remove the sub frame bolts (A).

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Fig. 158: Removing Sub Frame Bolts

Courtesy of HYUNDAI MOTOR CO.

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Fig. 159: Removing Sub Frame Bolts

Courtesy of HYUNDAI MOTOR CO.

36. Remove the engine support fixture and the adapter.

37. Jack up the vehicle.

INSTALLATION

Installation is in the reverse order of removal.

Perform the following :

Adjust the shift cable.

Adjust the throttle cable.
Refill the engine with engine oil.

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Refill the transaxle with fluid.

Refill the radiator with engine coolant.
Bleed air form the cooling system with the heater valve open.
Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
Inspect for fuel leakage.

After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the from
pump runs for approximately two seconds and fuel line pressurizes.

Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

ENGINE BLOCK
COMPONENT

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Fig. 160: Identifying Engine Block Components With Torque Specifications (1 Of 2)

Courtesy of HYUNDAI MOTOR CO.

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Fig. 161: Identifying Engine Block Components With Torque Specifications (2 Of 2)

Courtesy of HYUNDAI MOTOR CO.

DISASSEMBLY

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1. M/T : remove flywheel.

2. A/T : remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing belt. (See REMOVAL).
5. Remove cylinder head. (See REMOVAL)
6. Remove oil level gauge assembly (A).

Fig. 162: Removing Oil Level Gauge Assembly

Courtesy of HYUNDAI MOTOR CO.

7. Remove knock sensor (A).

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Fig. 163: Removing Knock Sensor

Courtesy of HYUNDAI MOTOR CO.

8. Remove oil pressure sensor (A).

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Fig. 164: Removing Oil Pressure Sensor

Courtesy of HYUNDAI MOTOR CO.

9. Remove water pump. (See REMOVAL)

10. Remove oil pan (A).

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Fig. 165: Removing Oil Pan

Courtesy of HYUNDAI MOTOR CO.

11. Remove oil screen. Remove the 2 bolts (C), oil screen (A) and gasket (B).

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Fig. 166: Removing Oil Screen

Courtesy of HYUNDAI MOTOR CO.

12. Check the connecting rod end play. (See INSPECTION)

13. Remove the connecting rod caps and check oil clearance. (See INSPECTION)
14. Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

NOTE: Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.

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15. Remove front case. (See INSTALLATION)

16. Remove rear oil seal case. Remove the 5 bolts (B) and rear oil seal case (A).

Fig. 167: Removing Rear Oil Seal Case

Courtesy of HYUNDAI MOTOR CO.

17. Remove crankshaft bearing cap and check oil clearance. (See INSPECTION)
18. Check the crankshaft end play.
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.

NOTE: Arrange the main bearings and trust washers in the correct order.

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Fig. 168: Removing Crankshaft Bearing Cap

Courtesy of HYUNDAI MOTOR CO.

20. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and
pin as a set.

21. Remove piston rings.

1. Using a piston ring expender, remove the 2 compression rings.
2. Remove the 2side rails and oil ring by hand.

NOTE: Arrange the piston rings in the correct order only.

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22. Disconnect connecting rod from piston.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using feeler gauge, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25 mm(0.004 ~ 0.010in.)

Maximum end play : 0.4 mm(0.016in.)

Fig. 169: Measuring End Play While Moving Connecting Rod Back And Forth
Courtesy of HYUNDAI MOTOR CO.

If out-of-tolerance, install a new connecting rod.

If still out-of-tolerance, replace the crankshaft.

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2. Check the connecting road bearing oil clearance.

1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap nuts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the nuts.

Tightening torque

50 ~ 53 Nm (500 ~ 530kgf.cm, 36.9 ~ 39lbf.ft)

NOTE: Do not turn the crankshaft.

7. Remove the 2 nuts, connecting rod cap and bearing half.

8. Measure the plastigage at its widest point.

Standard oil clearance

0.024 ~ 0.042 mm (0.0009 ~ 0.0017in.)

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Fig. 170: Measuring Plastigage At Its Widest Point

Courtesy of HYUNDAI MOTOR CO.

9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

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Fig. 171: Identifying Connecting Rod Mark Location

Courtesy of HYUNDAI MOTOR CO.

CONNECTING ROD INNER DIAMETER

CLASS MARK INSIDE DIAMETER
a WHITE 48.00 ~ 48.006 mm (1.8896~ 1.8899in.)

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b NONE 48.006~48.012 mm (1.8899~ 1.8902in.)

c YELLOW 48.012~48.018 mm (1.8902 ~ 1.8904in.)

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Fig. 172: Identifying Crankshaft Pin Mark Location

Courtesy of HYUNDAI MOTOR CO.

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CRANKSHAFT OUTSIDE DIAMETER

CLASS MARK OUTSIDE DIAMETER OF PIN
I 1 44.960 ~ 44.966 mm (1.7700 ~ 1.7703in.)
II 2 44.952 ~ 44.960 mm (1.7698~ 1.7700in.)
III 3 44.946 ~ 44.952 mm (1.7696 ~ 1.7698in.)

Fig. 173: Identifying Identification Mark (Connecting Rod Bearing)

Courtesy of HYUNDAI MOTOR CO.

CONNECTING ROD BEARING SPECIFICATIONS

CLASS MARK THICKNESS OF BEARING
AA BLUE 1.514~ 1.517 mm (0.0596 ~ 0.0597in.)
A BLACK 1.511 ~ 1.514 mm (0.0595 ~ 0.0596in.)
B NONE 1.508~ 1.511 mm (0.0594 ~ 0.0595in.)
C GREEN 1.505 ~ 1.508 mm (0.0593 ~ 0.0594in.)
D YELLOW 1.502~ 1.505 mm (0.0591 ~ 0.0593in)

11. Selection

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CONNECTING ROD BEARING SELECTION

ASSEMBLING
CRANKSHAFT CONNECTING ROD
CLASSIFICATION OF
INDEMNIFICATION MARK IDENTIFICATION MARK
BEARING
a (WHITE) D (YELLOW)
I (YELLOW) b (NONE) C (GREEN)
c (YELLOW) B (NONE)
a (WHITE) C (GREEN)
II (NONE) b (NONE) B (NONE)
c (YELLOW) A (BLACK)
a (WHITE) B (NONE)
III (WHITE) b (NONE) A (BLACK)
c (YELLOW) AA (BLUE)

3. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.

Tightening torque

30Nm (300kgf.cm, 22lbf.ft) + 60° - 65°

NOTE: Do not turn the crankshaft.

5. Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance

0.028 ~ 0.046 mm (0.0011 ~ 0.0018in.)

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Fig. 174: Measuring The Widest Part Of Plastigage

Courtesy of HYUNDAI MOTOR CO.

6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a
new, complete bearing with the same color mark (select the color as shown in the next column),
and recheck the clearance.

CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.

7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the
color listed above or below that one), and check clearance again.

NOTE: If the proper clearance cannot be obtained by using the appropriate

larger or smaller bearings, replace the crankshaft and start over.

CAUTION: If the marks are indecipherable because of an accumulation of

dirt and dust, do not scrub them with a wire brush or scraper.
Clean them only with solvent or detergent.

Connecting rods

1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make sure that the notches for holding the bearing in

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place are on the same side.

2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a
severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as
well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to
the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted
should be replaced.

Allowable bend of connecting rod :

0.05 mm / 100 mm (0.0020 in./3.94 in.) or less

Allowable twist of connecting rod :

0.1 mm / 100 mm (0.0039 in./3.94 in.) or less

Crankshaft Bore Mark Location

Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal
bores.

Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the
correct bearings.

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Fig. 175: Locating Crankshaft Bore Mark

Courtesy of HYUNDAI MOTOR CO.

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CYLINDER BLOCK INSIDE DIAMETER

CLASS MARK INSIDE DIAMETER
a A 61.000 ~ 61.006 mm (2.4015~2.4018in.)
b B 61.006~61.012 mm (2.4018 ~2.4020in.)
c C 61.012~61.018 mm (2.4020 ~ 2.4023in.)

Crankshaft Journal Mark Location

Fig. 176: Identifying Crankshaft Journal Mark Location

Courtesy of HYUNDAI MOTOR CO.

CRANKSHAFT OUTSIDE DIAMETER

CLASS MARK OUTSIDE DIAMETER OF JOURNAL
I YELLOW 56.956 ~ 56.962 mm (2.2423 ~ 2.2426in.)
II NONE 56.948 ~ 56.956 mm (2.2420 ~ 2.2423in.)
III WHITE 56.942 ~ 56.948 mm (2.2418 ~2.2420in.)

Place Of Identification Mark (Crankshaft Bearing)

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Fig. 177: Identifying Crankshaft Bearing Identification Mark

Courtesy of HYUNDAI MOTOR CO.

CRANKSHAFT BEARING SPECIFICATION

CLASS MARK THICKNESS OF BEARING
AA BLUE 2.014~2.017 mm (0.0793 ~ 0.0794in.)
A BLACK 2.011 ~ 2.014 mm (0.0791 ~ 0.0793in.)
B NONE 2.008~2.011 mm (0.0790~0.0791 in.)
C GREEN 2.005 ~ 2.008 mm (0.0789 ~ 0.0790in.)
D YELLOW 2.002 ~ 5.005 mm (0.0788 ~ 0.0789in.)

CRANKSHAFT BEARING SELECTION

CRANKSHAFT
CRANKSHAFT BORE ASSEMBLING
IDENTIFICATION IDENTIFICATION CLASSIFICATION
MARK MARK OF BEARING
I (YELLOW) a (A) D (YELLOW)
b (B) C (GREEN)
c (C) B (NONE)

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II (NONE) a (A) C (GREEN)

b (B) B (NONE)
c (C) A (BLACK)
III (WHITE) a (A) B (NONE)
b (B) A (BLACK)
c (C) AA (BLUE)

4. 4. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.

Standard end play

0.06 ~ 0.26 mm (0.0023 ~ 0.010in.)

Limit : 0.30 mm (0.0118in.)

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Fig. 178: Measuring Thrust Clearance

Courtesy of HYUNDAI MOTOR CO.

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness

2.44 ~ 2.47 mm(0.096 ~ 0.097in.)

5. 5. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter: 57 mm (2.244in.)

Crank pin diameter: 45 mm (1.77in.)

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Fig. 179: Measuring Diameter Of Each Main Journal And Crank Pin Using Micrometer
Courtesy of HYUNDAI MOTOR CO.

CYLINDER BLOCK

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1. Remove gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.03 mm (0.0012 in.)

Limit : 0.05 mm (0.0020 in.)

Fig. 180: Measuring Surface Contacting Cylinder Head Gasket For Warpage
Courtesy of HYUNDAI MOTOR CO.

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4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.

5. Inspect cylinder bore diameter

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial
directions.

Standard diameter

82.00 ~ 82.03 mm (3.2283 ~ 3.2295in.)

Fig. 181: Inspecting Cylinder Bore Diameter

Courtesy of HYUNDAI MOTOR CO.

6. Check the cylinder bore size code on the cylinder block bottom face.

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Fig. 182: Checking Cylinder Bore Size Code

Courtesy of HYUNDAI MOTOR CO.

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CYLINDER BORE INNER DIAMETER

Class Cylinder bore inner diameter Size code
A 82.00 ~ 82.01 mm (3.2283 ~ 3.2287in.) A
B 82.01 ~ 82.02 mm (3.2287 ~ 3.2291 in.) B
C 82.02 ~ 82.03 mm (3.2291 ~ 3.2295in.) C

7. Check the piston size code (A) on the piston top face

Fig. 183: Checking Piston Size Code

Courtesy of HYUNDAI MOTOR CO.

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NOTE: Stamp the grade mark of basic diameter with rubber stamp

CYLINDER BORE INNER DIAMETER

Class Cylinder bore inner diameter Size code
A 81.97 ~ 81.98 mm (3.2271 ~ 3.2275in.) A
B 81.98 ~ 81.99 mm (3.2275 ~ 3.2279in.) None
C 81.99 ~ 82.00 mm (3.2279 ~ 3.2283in.) C

8. Select the piston related to cylinder bore class.

Clearance

0.02 ~ 0.04 mm (0.00078 ~ 0.00157 in.)

Boring cylinder

1. Oversize pistons should be selected according to the largest bore cylinder.

PISTON SPECIFICATION
Identification Mark Size
0.25 0.25 mm (0.010in.)
0.50 0.50 mm (0.020in.)

NOTE: The size of piston is stamped on top of the piston.

2. Measure the outside diameter of the piston to be used.

3. According to the measured O.D., calculate the new bore size.

New bore size = Piston O.D + 0.02 to 0.04 mm (0.0008 to 0.0016 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.)

4. Bore each of the cylinders to the calculated size.

CAUTION: To prevent distortion that may result from temperature rise during
honing, bore the cylinder holes In the firing order.

5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

Standard : 0.02-0.04 mm (0.0008-0.0016 in.)

NOTE: When boring the cylinders, finish all of the cylinders to the same oversize.
Do not bore only one cylinder to the oversize.

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PISTON AND RINGS

1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.

NOTE: Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 47 mm (1.85 in.) from the top land of
the piston.

Standard diameter

81.97 ~ 82.00 mm (3.2272 ~ 3.2283 in.)

Fig. 184: Measuring Piston

Courtesy of HYUNDAI MOTOR CO.

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3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance

0.02 ~ 0.04 mm(0.0008 ~ 0.0016in.)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance

No. 1 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)

No. 2 : 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)

Limit

No. 1 : 0.1 mm (0.004 in.)

No. 2 : 0.1 mm (0.004 in.)

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Fig. 185: Measuring Piston Ring Side Clearance

Courtesy of HYUNDAI MOTOR CO.

If the clearance is greater than maximum, replace the piston.

5. Inspect piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder

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bore diameter against the wear limits. If the bore is over the service limit, the cylinder block must be
rebored. (See BORING CYLINDER).

Piston ring end gap

Standard

No. 1 : 0.23 ~ 0.38 mm (0.0091 ~ 0.0150 in.)

No. 2 : 0.33 ~ 0.48 mm (0.0130 ~ 0.0189 in.)

Limit

No. 1, 2, oil ring : 1.0 mm (0.039 in.)

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Fig. 186: Measuring Gap Using Feeler Gauge

Courtesy of HYUNDAI MOTOR CO.

PISTON PINS

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1. Measure the diameter of the piston pin.

Piston pin diameter

20.001 ~ 20.006 mm (0.7874 ~ 0.7876 in.)

Fig. 187: Measuring Diameter Of Piston Pin

Courtesy of HYUNDAI MOTOR CO.

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance

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0.01 ~ 0.02 mm (0.0004 ~ 0.0008 in.)

3. Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference

0.016 ~ 0.032 mm (0.00063 ~ 0.00126 in.)

OIL PRESSURE SWITCH

1. Check the continuity between terminal and the body with an ohmmeter.

If there is no continuity, replace the oil pressure switch.

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Fig. 188: Checking Continuity Between Terminal

Courtesy of HYUNDAI MOTOR CO.

2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is
continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50 kpa (7 psi) vacuum is applied through the oil hole, the switch is
operating properly.

Check for air leakage. If air leaks, the diaphragm is broken. Replace it

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Fig. 189: Checking Continuity Between Terminal And Body

Courtesy of HYUNDAI MOTOR CO.

REASSEMBLY

NOTE: Thoroughly clean all parts to assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating
surfaces.
Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.

1. Use a hydraulic press for installation.

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2. The piston front mark and the connecting rod front mark must face the timing belt side of the
engine.

Fig. 190: Identifying Piston Marks

Courtesy of HYUNDAI MOTOR CO.

2. Install piston rings.

1. Install the oil ring expander and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown in Fig. 191.

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Fig. 191: Positioning Piston Rings

Courtesy of HYUNDAI MOTOR CO.

3. Install connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).

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Fig. 192: Installing Bearings In Connecting Rod

Courtesy of HYUNDAI MOTOR CO.

4. Install main bearings.

NOTE: Upper 1,2,4,5 bearings have an oil groove of oil holes; Lower bearings do
not.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings
(A).

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Fig. 193: Aligning Bearing Claw

Courtesy of HYUNDAI MOTOR CO.

2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower
bearings.
5. Install thrust bearings.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves
facing outward.

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Fig. 194: Installing Thrust Bearings

Courtesy of HYUNDAI MOTOR CO.

6. Place crankshaft on the cylinder block.

7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts.

NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.

1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown
in Fig. 195.

Tightening torque : 30Nm (300kgf.cm, 22lbf.ft)

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Fig. 195: Tightening Bearing Caps

Courtesy of HYUNDAI MOTOR CO.

3. Retighten the bearing cap bolts by 60°~65° in the numerical order shown in Fig. 195.

Tightening torque

Main bearing cap bolt :

30Nm (300kgf.cm, 22lbf.ft) + 60° ~ 65°

4. Check that the crankshaft turns smoothly.

9. Check crankshaft end play.
10. Install piston and connecting rod assemblies.

NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves

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and cylinder bores.

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of
the connecting rod bolts.
2. Install the ring compressor, check that the bearing is securely in place, then position the piston in
the cylinder, and tap it in using the wooden handle of a hammer.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the nuts : 50 ~
53Nm (500 ~ 530kgf.cm, 36.9 ~ 39lbf.ft)

NOTE: Maintain downward force on the ring compressor to prevent the rings
from expanding before entering the cylinder bore.

Fig. 196: Installing Rod Caps

Courtesy of HYUNDAI MOTOR CO.

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11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).

Tightening torque

10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)

Fig. 197: Installing Gasket And Rear Oil Seal Case

Courtesy of HYUNDAI MOTOR CO.

NOTE: Check that the mating surfaces are clean and dry.

12. Install rear oil seal.

1. Apply engine oil to a new oil seal lip.
2. Using SST(09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil
seal retainer edge.

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Fig. 198: Applying Engine Oil To Oil Seal Lip

Courtesy of HYUNDAI MOTOR CO.

13. Install front case. (See INSTALLATION)

14. Install oil screen.

Install a new gasket (B) and oil screen (A) with 2 bolts (C).

Tightening torque

15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)

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Fig. 199: Installing Oil Screen

Courtesy of HYUNDAI MOTOR CO.

15. Install oil pan.

1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket
surfaces.

NOTE: Check that the mating surfaces are clean and dry before applying
liquid gasket.

2. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Use liquid
gasket MS 721-40A or equivalent.

NOTE: To prevent leakage of oil, apply liquid gasket to the inner

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threads of the bolt holes.

Do not install the parts if five minutes or more have elapsed
since applying the liquid gasket. Instead, reapply liquid gasket
after removing the residue.
After assembly, wait at least 30 minutes before filling the engine
with oil.

3. Install the oil pan (A) with the 19 bolts. Uniformly tighten the bolts in several passes.

Tightening torque

10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)

Fig. 200: Installing Oil Pan

Courtesy of HYUNDAI MOTOR CO.

16. Install water pump. (See INSTALLATION)

17. Install oil pressure sensor.

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1. Apply adhesive to 2 or 3 threads. Adhesive : MS 721-39 (B) or equivalent.

2. Install the oil pressure sensor (A).

Tightening torque

15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)

Fig. 201: Installing Oil Pressure Sensor

Courtesy of HYUNDAI MOTOR CO.

18. Install knock sensor (A).

Tightening torque

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17 ~ 27Nm (170 ~ 270kgf.cm, 12.5 ~ 20lbf.ft)

Fig. 202: Installing Knock Sensor

Courtesy of HYUNDAI MOTOR CO.

19. Install oil level gauge assembly.

1. Install a new O-ring on the oil level gauge.
2. Apply engine oil on the O-ring.
3. Install the oil level gauge assembly (A) with the bolt.

Tightening torque

12 ~ 15Nm (120 ~ 150kgf.cm, 9 ~11lbf.ft)

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Fig. 203: Installing Oil Level Gauge Assembly

Courtesy of HYUNDAI MOTOR CO.

20. Install cylinder head. (See INSTALLATION)

21. Install timing belt. (See INSTALLATION)
22. Remove engine stand.
23. A/T : Install drive plate.

Tightening torque

120 ~130Nm (1200 ~1300kgf.cm, 89 ~ 96lbf.ft)

24. M/T : Install flywheel.

Tightening torque

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120~ 130Nm (1200 ~ 1300kgf.cm, 89 ~ 96lbf.ft)

COOLING SYSTEM
COMPONENT

Fig. 204: Identifying Cooling System Components With Torque Specifications (1 Of 2)

Courtesy of HYUNDAI MOTOR CO.

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Fig. 205: Identifying Cooling System Components With Torque Specifications (2 Of 2)

Courtesy of HYUNDAI MOTOR CO.

ENGINE COOLANT REFILLING AND BLEEDING

CAUTION: When pouring engine coolant, be sure to shut the relay box lid and not to
let coolant spill on the electrical parts or the paint. If any coolant spills,
rinse it off immediately.

1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to
the touch.
2. Remove radiator cap (A).

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Fig. 206: Removing Radiator Cap

Courtesy of HYUNDAI MOTOR CO.

3. Loosen the drain plug, and drain the coolant.

4. Tighten the radiator drain plug (A) securely.

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Fig. 207: Loosening Drain Plug

Courtesy of HYUNDAI MOTOR CO.

5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to
the MAX mark with antifreeze.
6. Mix the recommended antifreeze with an equal amount of water in a clean container.

NOTE: Use only genuine antifreeze/coolant.

For best corrosion protection, the coolant concentration must be
maintained year-round at 50% minimum. Coolant concentrations less
than 50% may not provide sufficient protection against corrosion or
freezing.
Coolant concentrations greater then 60% will impair cooling
efficiency and are not recommended.

CAUTION: Do not mix different brands of antifreeze / coolants.

Do not use additional rust inhibitors or anti-rust products; they

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may not be compatible with the coolant.

7. Pour coolant into the radiator up to base of the filler neck, and install the radiator cap loosely.
8. Start the engine and let it run until it warms up (the radiator fan comes on at least twice).
9. Turn off the engine. Check the level in the radiator, add coolant if needed.
10. Put the radiator cap on tightly, then run the engine again and check for leaks.

CAP TESTING

1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.

Fig. 208: Identifying Pressure Tester

Courtesy of HYUNDAI MOTOR CO.

2. Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm2 , 14 ~ 19psi)

3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

TESTING

1. Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm2 14 ~
19psi).

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Fig. 209: Applying Pressure Tester To Radiator

Courtesy of HYUNDAI MOTOR CO.

3. Inspect for engine coolant leaks and a drop in pressure.

4. Remove the tester and reinstall the radiator cap.

NOTE: Check for engine oil in the coolant and/or coolant in the engine oil.

REMOVAL

WATER PUMP

1. Drain the engine coolant.

WARNING: System is under high pressure when the engine is hot. To avoid
danger of releasing scalding engine coolant, remove the cap only
when the engine is cool.

2. Remove drive belts.

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3. Remove the timing belt. (See REMOVAL)

4. Remove the timing belt idler. (See 15)
5. Remove the water pump.
1. Remove the 4 bolts and pump pulley.
2. Remove the 2 bolts (C), then remove the alternator brace (A).
3. Remove the water (B) pump and gasket.

Fig. 210: Removing Water Pump And Gasket

Courtesy of HYUNDAI MOTOR CO.

THERMOSTAT

NOTE: Removal of the thermostat would have an adverse effect, causing a lowering of
cooling efficiency. Do not remove the thermostat, even if the engine tends to
overheat.

1. Drain engine coolant so its level is below thermostat.

2. Remove water inlet (A), gasket and thermostat.

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Fig. 211: Removing Water Inlet Gasket And Thermostat

Courtesy of HYUNDAI MOTOR CO.

RADIATOR

1. Drain the engine coolant.

2. Remove the upper and lower radiator hoses (A), and ATF cooler hoses.

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Fig. 212: Removing Upper And Lower Radiator Hoses

Courtesy of HYUNDAI MOTOR CO.

3. Disconnect the fan motor connector (A).

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Fig. 213: Disconnecting Fan Motor Connector

Courtesy of HYUNDAI MOTOR CO.

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Fig. 214: Disconnecting Fan Motor Connector

Courtesy of HYUNDAI MOTOR CO.

4. Separate the air conditioner condenser with radiator.

1. Remove the heat shield.
2. Remove the battery and battery tray.
3. Remove the air duct (A) and make the task space.

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Fig. 215: Removing Air Duct

Courtesy of HYUNDAI MOTOR CO.

4. Remove the reservoir tank (A) and make the task space.

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Fig. 216: Removing Reservoir Tank

Courtesy of HYUNDAI MOTOR CO.

5. Remove the 10 mm bolt (A).

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Fig. 217: Removing Bolt

Courtesy of HYUNDAI MOTOR CO.

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Fig. 218: Locating Bolt

Courtesy of HYUNDAI MOTOR CO.

5. Remove the radiator upper bracket (A), then pull up the radiator.

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Fig. 219: Removing Radiator Upper Bracket

Courtesy of HYUNDAI MOTOR CO.

6. Remove the cooling fan from the radiator.

INSPECTION

WATER PUMP

1. Check each part for cracks, damage or wear, and replace the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and sluggish rotation, and replace the coolant pump
assembly if necessary.

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Fig. 220: Checking Bearing For Damage

Courtesy of HYUNDAI MOTOR CO.

3. Check for coolant leakage. If coolant leaks from hole, the seal is defective. Replace the coolant pump
assembly

NOTE: A small amount of "weeping" from the bleed hole is normal.

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THERMOSTAT

1. Immerse the thermostat in water and gradually heat the water.

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Fig. 221: Immersing Thermostat In Water

Courtesy of HYUNDAI MOTOR CO.

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2. Check the valve opening temperature.

Valve opening temperature : 82°C (177°F)

Full opening temperature : 95°C (205°F)

If the valve opening temperature is not as specified, replace the thermostat.

3. Check the valve lift.

Valve lift: 8 mm (0.3in.) or more at 95°C (205°F)

If the valve lift is not as specified, replace the thermostat.

INSTALLATION

WATER PUMP

1. Install the water pump.

1. Install the water pump (B) and a new gasket with the 3 bolts.

Tightening torque

20 ~ 27Nm (200 ~ 270kgf.cm, 15 ~ 20lbf.ft)

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Fig. 222: Installing Water Pump

Courtesy of HYUNDAI MOTOR CO.

2. Install the alternator brace (A) with the 2 bolts (C).

3. Install the 4 bolts and pump pulley.
2. Install the timing belt idler. (See 5)
3. Install the timing belt. (See INSTALLATION)
4. Install drive belts.
5. Fill with engine coolant.
6. Start engine and check for leaks.
7. Recheck engine coolant level.

THERMOSTAT

1. Place thermostat in thermostat housing.

1. Install the thermostat with the jiggle valve upward.
2. Install a new gasket (A) to the thermostat (B).

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Fig. 223: Installing Thermostat With Jiggle Valve Upward

Courtesy of HYUNDAI MOTOR CO.

2. Install water inlet (A).

Tightening torque

15 ~ 20Nm (150 ~ 200kf.cm, 9 ~14lbf.ft)

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Fig. 224: Installing Water Inlet

Courtesy of HYUNDAI MOTOR CO.

3. Fill with engine coolant.

4. Start engine and check for leaks.

RADIATOR

1. Install the cooling fan to the radiator.

2. Install the radiator at the air conditioner condenser. Installation is in the reverse order of removal.
3. Connect the fan motor connector.
4. Install the upper and lower radiator hoses, and ATF cooler hoses.
5. Fill with engine coolant.
6. Start engine and check for leaks.

LUBRICATION SYSTEM
COMPONENT

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Fig. 225: Identifying Lubrication System Components With Torque Specifications (1 Of 2)

Courtesy of HYUNDAI MOTOR CO.

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Fig. 226: Identifying Lubrication System Components With Torque Specifications (2 Of 2)

Courtesy of HYUNDAI MOTOR CO.

OIL AND FILTER

CAUTION: Prolonged and repeated contact with mineral oil will result in the
removal of natural fats from the skin, leading to dryness, irritation
and dramatist. In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
Exercise caution in order to minimize the length and frequency of
contact of your skin to used oil. Wear protective clothing and gloves.
Wash your skin thoroughly with soap and water, or use water-less
hand cleaner, to remove any used engine oil. Do not use gasoline,

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thinners, or solvents.
In order to preserve the environment, used oil and used oil filter must
be disposed of only at designated disposal sites.

1. Drain engine oil.

a. Remove the oil filter cap.
b. Remove the oil drain plug, and drain the oil into a container.
2. Replace oil filter.
a. Remove the oil filter.
b. Check and clean the oil filter installation surface.
c. Check the part number of the new oil filter is as same as old one.
d. Apply clean engine oil to the gasket of a new oil filter.
e. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
f. Tighten it an additional 3/4 turn.
3. Refill with engine oil filter.
a. Clean and install the oil drain plug with a new gasket.

Tightening torque

40 ~ 45Nm (400 ~ 450kgf.cm, 30 ~ 33lbf.ft)

b. Fill with fresh engine oil

Capacity

Drain and refill :

W/Oil filter change : 4.0I (4.23U.S.qts, 3.52Imp qts)

W/O Oil filter change : 3.7I (3.90U.S. qts, 3.26Imp qts)

c. Install the oil filter cap.

4. Start engine and check for oil leaks.
5. Recheck engine oil level.

INSPECTION

1. Check engine oil quality

Check the oil for deterioration, entry of water, discoloring or thinning.

If the quality is visibly poor, replace the oil.

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2. Check engine oil level.

After warming up the engine and then 5 minutes after the engine stop, oil level should be between the "L"
and "F" marks on the dipstick.

If low, check for leakage and add oil up to the "F" mark.

NOTE: Do not fill with engine oil above the "F" mark.

SELECTION OF ENGINE OIL

Recommended API classification : SH OR ABOVE

Recommended SAE viscosity grades :

W/O-CVVT

Fig. 227: Recommended API Classification : SH Or Above

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Courtesy of HYUNDAI MOTOR CO.

W/CVVT

Fig. 228: Recommended API Classification : W/CVVT

Courtesy of HYUNDAI MOTOR CO.

NOTE: For best performance and maximum protection of all types of operation, select
only those lubricants which

1. Satisfy the requirement of the API classification.

2. Have proper SAE grade number for expected ambient temperature range.

Lubricants that do not have both an SAE grade number and API service
classification on the container should not be used.

REMOVAL

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1. Drain engine oil.

2. Remove the drive belts.
3. Turn the crankshaft and align the white groove on the crankshaft pulley with the pointer on the lower
cover. (See a)
4. Remove the timing belt. (See REMOVAL)
5. Remove the oil pan and oil screen. (See DISASSEMBLY)
6. Remove the front case.

Fig. 229: Removing Front Case

Courtesy of HYUNDAI MOTOR CO.

1. Remove the screws (B) from the pump housing, then separate the housing and cover (A).

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Fig. 230: Removing Screws From Pump Housing

Courtesy of HYUNDAI MOTOR CO.

2. Remove the inner (A) and outer (B) rotors.

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Fig. 231: Removing Inner And Outer Rotors

Courtesy of HYUNDAI MOTOR CO.

DISASSEMBLY

1. Remove the relief plunger.

Remove the plug (A), spring (B) and relief plunger (C).

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Fig. 232: Removing Relief Plunger

Courtesy of HYUNDAI MOTOR CO.

INSPECTION

1. Inspect relief plunger.

Coat the valve with engine oil and check that it falls smoothly into the plunger hole by its own weight. If
it does not, replace the relief plunger. If necessary, replace the front case.

2. Inspect relief valve spring.

Inspect for distorted or broken relief valve spring.

Standard value

Free height: 43.8 mm (1.724 in.)

Load : 3.7kg/40.1 mm (8.14 lb/1.579 in.)

3. Inspect rotor side clearance.

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Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision
straight edge.

SIDE CLEARANCE SPECIFICATION

Outer gear 0.04 ~ 0.09 mm (0.0016 ~0.0035in.)
Side clearance
Inner gear 0.04 ~ 0.085 mm (0.0016 ~0.0033in.)

Fig. 233: Measuring Clearance Between Rotors And Precision Straight Edge
Courtesy of HYUNDAI MOTOR CO.

If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front
case.

4. Inspect rotor tip clearance.

Using a feeler gauge, measure the tip clearance between the inner and outer rotor tips.

Tip clearance

0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.)

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Fig. 234: Inspecting Rotor Tip Clearance

Courtesy of HYUNDAI MOTOR CO.

If the tip clearance is greater than maximum, replace the rotor as a set.

5. Inspect rotor body clearance.

Using a feeler gauge, measure the clearance between the outer rotor and body.

Body clearance

0.12 ~ 0.185 mm (0.0047 ~ 0.0073 in.)

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Fig. 235: Measuring Clearance Between Outer Rotor And Body

Courtesy of HYUNDAI MOTOR CO.

If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the front
case.

REASSEMBLY

1. Install relief plunger.

Install relief plunger (C) and spring (B) into the front case hole, and install the plug (A).

Tightening torque

40 ~ 50Nm (400 ~ 500kgf.cm, 30 ~ 37lbf.ft)

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Fig. 236: Installing Relief Plunger

Courtesy of HYUNDAI MOTOR CO.

INSTALLATION

1. Install oil pump.

1. Place the inner and outer rotors into front case with the marks facing the oil pump cover side.
2. Install the oil pump cover (A) to front case with the 7 screws (B).

Tightening torque

6 ~ 9Nm (60 ~ 90kgf.cm, 4.4 ~ 6.6lbf.ft)

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Fig. 237: Installing Oil Pump Cover

Courtesy of HYUNDAI MOTOR CO.

2. Check that the oil pump turns freely.

3. Install the oil pump on the cylinder block.

Place a new front case gasket on the cylinder block. Apply engine oil to the lip of the oil pump seal. Then,
install the oil pump onto the crankshaft. When the pump is in place, clean any excess grease off the
crankshaft and check that the oil seal lip is not distorted.

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Fig. 238: Installing Oil Pump On Cylinder Block

Courtesy of HYUNDAI MOTOR CO.

Body length

A. : 25 mm (0.98 in)
B. : 20 mm (0.787 in)
C. : 38 mm (1.496 in)
D. : 45 mm (1.771 in)

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Tightening torque

20 ~ 27Nm (200 ~ 270kg.cm, 14.5 ~ 19.8 lb.ft)

4. Apply a light coat of oil to the seal lip.

5. Using the SST(09214-33000), install the oil seal.

Fig. 239: Installing Oil Seal

Courtesy of HYUNDAI MOTOR CO.

6. Install the oil screen. (See 14)

7. Install the oil pan. (See 15)

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NOTE: Clean the oil pan gasket mating surfaces.

INTAKE AND EXHAUST SYSTEM

COMPONENT

INTAKE MANIFOLD

Fig. 240: Identifying Intake Manifold Components With Torque Specifications

Courtesy of HYUNDAI MOTOR CO.

EXHAUST MANIFOLD

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Fig. 241: Identifying Exhaust Manifold Components With Torque Specifications

Courtesy of HYUNDAI MOTOR CO.

MUFFLER

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2005 ENGINE Engine Mechanical System (G4GC - GLS 2.0L) - Elantra

Fig. 242: Identifying Intake And Exhaust System Components - Muffler With Torque Specifications
Courtesy of HYUNDAI MOTOR CO.

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