|
BOLT GUIDELINE FOR REUES & TORQUE SPECIFICATIONS |
Engine Bolt Reuse Guidelines & Torque Specifications For
1996-2003 Hyundai Engines
The AERA Technical Committee offers the following information regarding engine bolt reuse guidelines & torque specifications for 1996-2003 Hyundai engines. This bulletin applies to the cylinder head, connecting rod and main bearing bolts that use the torque angle method for tightening.
It has been determined fasteners that are tightened by the conventional torque only method can have substantial clamping force variation. These variations come from several factors such as fastener friction and hand tightening versus power driver tightening methods. Fasteners that are tightened by a low initial torque value plus tightened and additional angular value are known as ?torque-angle bolts" (or sometimes torque-to-yield bolts). These types of bolts or fasteners can achieve very high clamp loads with very small variation.
YEAR MODEL ENGINE COMPONENT TORQUE REUSE GUIDELINE
2000-2002 Accent 1.5L Cylinder Head 8 ft/lbs + 60° + 60° Unlimited Reuse
2001-2002 Accent 1.6L Cylinder Head 26 ft/lbs+ 90° loosen, 26 ft/lbs+90° Unlimited Reuse
1997-2001 Tiburon 1.8L & 2.0L Cylinder Head M10: 22 ft/lbs+ 60° + 60°M12: 26 ft/lbs + 60° + 60° Unlimited Reuse
1997-2001 Tiburon 1.8L & 2.0L Main Bearing 22 ft/lbs + 60° Unlimited Reuse
1997-2001 Tiburon 1.8L & 2.0L Connecting Rod 37-39 ft/lbs No Torque Angle ? Reuse Guidelines Do not apply
2003 Tiburon 2.0L Cylinder Head M10: 18 ft/lbs+ 60° + 60°M12: 22 ft/lbs + 60° + 60° Unlimited Reuse
2001-20021999-2002 Santa FeSonata 2.4L Cylinder Head 47 ft/lbs then loosen bolts, 15 ft/lbs + 90° + 90° Reuse only if shank of bolt is 3.91" or shorter
2001-20021999-2002 Santa FeSonata 2.4L Main Bearing 18 ft/lbs + 90° Reuse only if shank of bolts is 2.79" or shorter
2001-20021999-2002 Santa FeSonata 2.4L Connecting Rod 15 ft/lbs + 90° Discard ? Do Not Reuse
1999-20022001-20022003 SonataSanta FeTiburon 2.5L & 2.7L2.7L2.7L Cylinder Head 18 ft/lbs + 60° + 45° Unlimited Reuse
1999-20022001-20022003 SonataSanta FeTiburon 2.5L & 2.7L2.7L2.7L Main Bearing M10: 22 ft/lbs + 90°M8: 12 ft/lbs + 90° Unlimited Reuse
1999-20022001-20022003 SonataSanta FeTiburon 2.5L & 2.7L2.7L2.7L Connecting Rod 13 ft/lbs + 90° Discard ? Do Not Reuse
2001-2002 XG 3.0L & 3.5L Connecting Rod 26 ft/lbs + 90° Discard ? Do Not Reuse
The AERA Technical Committee |
|
REVISED CRANKSHAFT DESIGN ON 1.8 & 2.0L HYUNDAI |
Revised Crankshaft Design For
1996-2000 Hyundai 1.8 & 2.0L Engines
The AERA Technical Committee offers the following information on 1996-2000 Hyundai 1.8 & 2.0L engines. Several other components including the flexplate/flywheel required changes to accommodate the new crankshaft designs. These engines are used in the Elantra and Tiburon car models.
The new crankshafts, Part #23110-23710 for the 2.0L and Part #23110-23510 for the 1.8L, were released July 8, 1999 and have the following dimensional changes as illustrated in Figure 1.
A. The flywheel mounting flange (pilot) diameter has been reduced from 1.614(41 mm) to 1.3780 (35 mm).
B. The flywheel mounting flange (pilot) height has been increased from .1575 (4 mm) to .2560 (6.5 mm).
C. The crankshaft rear flange thickness has been reduced from .8071 (20.5 mm) to .7087(18 mm).
D. The crankshaft rear flange bolt hole depth has been reduced from .5315-.6496 (13.5-16.5 mm) to .4528-.5512 (11.5 mm -14 mm).
NOTE: The new crankshafts are not interchangeable with the previous ones. However, a crankshaft spacer (Part #23112-23900) can be attached to the new crankshafts to make them interchangeable with the older crankshafts.
The flywheel and flex plate assemblies have also been changed to fit the new crankshaft. The new flywheel and flex plate assemblies are not backward compatible with the older crankshaft. However, the older flywheel and flex plate can be made interchangeable by mounting a crankshaft spacer (Part #23112-23900) onto the new style crankshaft.
· The flywheel and flex plate assembly pilot bore diameter has been reduced from 1.6142 (41 mm) to 1.3780 (35 mm).
· The flywheel pilot bore depth has been increased from .1969 (5.0 mm) to .2953 (7.5 mm).
Each crankshaft and flywheel / flexplate combination necessitates that specific mounting bolts to the crankshaft are used. Tables 1 and 2 identify the different combinations for manual and automatic transaxles.
The AERA Technical Committee |
|
CAM TO CAM TIMING FOR 2.0L DOHC HYUNDAI ENGINES |
Camshaft-To-Camshaft Timing Caution On
Hyundai Elantra, Tiburon 2.0L DOHC 2001-2003
AERA members report that an error was made in the Hyundai OEM engine shop manual covering 2001-2002 Elantra and the 2003 Tiburon vehicles. The diagram used to show camshaft-to-camshaft timing is incorrect in the manuals for the above-mentioned vehicles. If the camshaft-to-camshaft timing is wrong the vehicle will run rough and set a DTC P0340 code.
Note that the CORRECT timing diagram shows that the keyway positions are located approximately at the 2:30 O?clock position and the blue colored timing chain links line up with both timing marks on the gears.
The incorrect diagram shows the left cam timing mark on the cam gear to be 1/2 link to the left of the blue timing link.
The AERA Technical Committee |
|
HEADBOLT TIGHTING SEQUENCE FOR 2001 HYUNDAI 2.0L ENGINES |
Head Bolt Tightening Sequence For
2001 Hyundai 2.0L Engines
The AERA Technical Committee offers the following information regarding the correct cylinder head tightening sequence for 2001 Hyundai 2.0L DOHC engines. Previously published information inadvertently showed the head bolt removal sequence.
To install the head on this engine refer to the following steps and also note Hyundai does not recommend reusing any head bolt more than once.
·Clean all gasket surfaces of the cylinder block and cylinder head and blow-dry with compressed air.
·Install a new cylinder head gasket; do not use any type of sealer or lubricant.
·Place the head onto engine and install all head bolts and tighten finger tight.
·Tighten all M10 bolts = 22 ft/lbs (30 Nm) and all M12 bolts to 26 ft/lbs (35 Nm) in sequence.
·Rotate all bolts in sequence 60°.
·Rotate all bolts again in sequence an additional 60° turn.
The AERA Technical Committee |
|
REVISED LASH ADJUSTMENT FOR 2001-03 HYUNDAI 2.0L ENGINES |
Revised Valve Lash Adjustment For
2001-2003 Hyundai 2.0L G4GF, VIN F Engines
The AERA Technical Committee offers the following information regarding a revised valve lash adjustment on 2001-2003 Hyundai 2.0L G4GF VIN F engines. Previous to 2001, these engines used a non-adjustable hydraulic lash compensator within the valve train. The current, revised, cam follower (non-hydraulic adjuster) requires an adjustment inspection every 60,000 miles or 48 months. The 2004 manuals have this updated information.
Valve lash adjustment should be made with a cold engine at 59°F-77° F. The cold valve lash for intake valves is .007-.009 (.178-.287 mm), while exhaust valve is .010-.012 (.254-.305 mm). If the correct valve lash cannot be set with the original hardened shims as shown in Figure 1, obtain a different thickness shim until the correct lash is present.
During disassembly of the camshafts and lash adjusters, mark their location for proper installation during re-assembly. During cylinder head repairs, such as grinding of the valves and seats, proper stem heights should be maintained. The valve stem height measurements for both intake and exhaust valves is 1.9200-1.9500 (48.768-49.53 MM).
Figure 1. Locations to measure Clearance.
The AERA Technical Committee |
|
NEW CYLINDER LINER O-RINGS |
New Cylinder Liner O-Ring Seals On
Cummins NH/NT 6 Cylinder Engines
Cummins Engine Company has released new O-ring seals for the cylinder liners in NH/NT 6 cylinder engines. The new seals are made of an EP material and have a smaller diameter cross-section.
The new seal replaces both the old center seal #3008998 and the old lower seal #183049. The new seal carries Cummins part #3032874 and is black in color with one blue dot.
The new O-ring seals are not to be intermixed with the former seals on the same liner. Cylinder liner deformation will result. You can use the former seals and new seals in the same engine as long as they are used in the correct combinations on each liner. The illustration below shows the correct combinations.
The AERA Technical Committee |
|
OIL IN COOLANT |
Oil in Cooling System on
VW 1.5L & 1.6L Diesel Engines
AERA members have reported instances of engine oil in the cooling system on VW 1.5L diesel engines. According to AERA sources, the problem is related to a crack in the cylinder head bolt hole located near the oil gallery feeding the cylinder head.
The oil feed gallery in the block is located on one side of the center head bolt hole and a coolant jacket is on the opposite side of the bolt hole. Pressurized engine oil is diverted through a slot in the head gasket and is feed up the side of the head bolt to the cylinder head. The oil also follows the bolt back down to the bottom of the bolt hole. Should the crack in the head bolt hole extend to the coolant jacket, oil can mix with engine coolant.
This problem is generally found on engines equipped with 11mm head bolt holes. Later design engines utilize 12mm head bolts and do not exhibit this defect. At the time of this writing no successful repair procedure is available.
The AERA Technical Committee |
