| 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 |
| LOOSE VALVE GUIDES |
Loose Valve Guides On
Hyundai 1.6L Engines
AERA member machine shops have reported finding loose valve guides in Hyundai 1.6L engine cylinder heads.
Hyundai has made oversize OD guides available for installation in cylinder heads where the original guide has become loose. The oversizes are .002 (.05mm), .010 (.25mm) and .020 (.50mm) and should be available at the local dealer under the following part numbers. Standard size OD valve guides are not available.
Intake Exhaust Cyl. Head Bore
Size Guide Part No. Guide Part No. in. (mm)
.002 MD000461 MD000471 .5138-.5145 (13.050-13.068mm)
.010 MD000462 MD000472 .5216-.5224 (13.249-13.269mm)
.025 MD000463 MD000473 .5315-.5323 (13.500-13.520mm)
The valve guide inside diameter should be finished to provide .0008-.0019 (.020-.048mm) of clearance for intake and .0020-.0033 (.050-.084mm) of clearance for the exhaust valve stem.
The installed valve guide height should be .539-.563 above the spring seat of the cylinder head.
The AERA Technical Committee |
| LOOSE GUIDES |
Loose Valve Guides On
Hyundai 1.6L Engines
AERA member machine shops have reported finding loose valve guides in Hyundai 1.6L engine cylinder heads.
Hyundai has made oversize OD guides available for installation in cylinder heads where the original guide has become loose. The oversizes are .002 (.05mm), .010 (.25mm) and .020 (.50mm) and should be available at the local dealer under the following part numbers. Standard size OD valve guides are not available.
Intake, Exhaust Cyl. Head Bore
Size Guide Part No. Guide Part No. in. (mm)
.002MD000461 MD000471 .5138-.5145 (13.050-13.068mm)
.010MD000462 MD000472 .5216-.5224 (13.249-13.269mm)
.025 MD000463 MD000473 .5315-.5323 (13.500-13.520mm)
The valve guide inside diameter should be finished to provide .0008-.0019 (.020-.048mm) of clearance for intake and .0020-.0033 (.050-.084mm) of clearance for the exhaust valve stem.
The installed valve guide height should be .539-.563 above the spring seat of the cylinder head.
The AERA Technical Committee |
| REVISED LASH ADJUSTER FOR HYUNDAI ENGINES |
Revised Lash Adjuster For
1992-2003 Hyundai 1.6,1.8, 2.0, 2.4, 3.0 & 3.5L Engines
The AERA Technical Committee offers the following information regarding a revised lash adjuster for 1992-2003 Hyundai engines. This lifter revision applies to all of the engines shown in the chart below used by Hyundai. The new larger hole lash adjuster has been installed on engines produced beginning October 2000.
The major visual difference between the two lifters is the oil hole opening size located at the top of the lifter as viewed in Figure 2. The oil hole opening was doubled in size from .059 (1.5 MM) to .118 (3.0 MM). The new lash adjuster assembly may be installed on the engines, if replaced as a set within the engine. It is not recommended to mix the two different adjusters.
The new hydraulic lash adjuster (P/N 24610-33050) with a larger oil hole has been released to reduce engine noise. AERA is aware of at least one aftermarket source at this time.
The AERA Technical Committee |
| REVISED OIL FILTER SEAL ON 1986-87 1.5L ENGINES |
Revised Oil Filter Seal
on 1986-87 Hyundai 1.5L (92 CID) Engines
Hyundai has modified the oil filter seal on the oil filter
assembly that is used on 1986-87 1.5L (92 CID) engines. The new
oil filter assembly, part #26300-21010, provides increased
sealing capabilities and is the only replacement part serviced by
Hyundai. While the oil filter has been revised, it still carries
the part number of the former filter.
You can differentiate between the former and the revised oil
filter assembly (Figure 1) by measuring the height of the sealing
ring (Figure 2). The revised sealing ring is .102 (2.6 mm)
tall, whereas the former sealing ring measures only .099 (2.4
mm). The width of the oil filter base contact side of the
sealing ring has also been increased by decreasing the sealing
ring taper.
Engines produced after March 4, 1987 carry the new oil filter.
Symbol * New Former
H .102 (2.6 mm) .099 (2.4 mm)
L 7o-8o 16o-20o
* See Figure 2
The AERA Technical Committee
January 1988 - SB 152
##END## |
| CONNECTING ROD ASSEMBLY CAUTION |
Connecting Rod Assembly Caution On
1986-94 Hyundai 1.5L VIN J Engines
The AERA Technical Committee offers the following connecting rod to piston assembly caution on 1986-94 Hyundai 1.5L VIN J engines. Failure to use the
correct procedures may result in loss of interference fit between the piston pin and rod during engine operating. Hyundai does not recommend using heat to
install the connecting rod on to the piston pin.
The recommended procedure from Hyundai is to press the piston pin into the connecting rod. While pressing the rod to the piston pin, make sure only 1,102-3,306 lbs of pressure is used to install the pin. If the force is lower than 1,102 lbs. replace the rod or fit the rod with an oversize piston pin. If over 3,306 lbs of force is required, hone the rod as required to achieve the factory assembly specifications.
NOTE: Do not exceed 5,000 lbs force while determining assembly pressure.
For Additional information, refer to AERA Technical Bulletin TB-1527.
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 |
| TIMING BELT NOISE ON 1999-2000 2.0L HYUNDAI ENGINES |
Timing Belt Noise On
1999-2000 Hyundai 2.0L Engines
The AERA Technical Committee offers the following information regarding a timing belt noise on 1999-2000 Hyundai 2.0L engines. Vehicles with front timing case assemblies manufactured before 9/22/99 may have a mismachined idler pulley mounting surface that is not parallel with the front face of the cylinder block. This can cause the timing belt to walk off the gears and into the front dust covers.
The timing belt rubbing against the front dust cover may be causing this type of noise. A frayed or shredded front edge may occur on the timing belt. The condition may be caused by the front case and is most likely to occur at low mileage.
Verify that this condition exists by removing the timing belt upper cover and inspecting the front edge of the timing belt for fraying/shredding (Figure 1) along with the backside of the upper cover for evidence of rubbing. Should any of these conditions exist, replace the front case, Part #21310-23002, idler pulley, Part #24810-23011, and the timing belt, Part #24312-23201.
The AERA Technical Committee |
