Hyundai 2004 Accent User manual

2004 ENGINES
1.6L 4-Cylinder - Accent
GENERAL
SPECIFICATIONS
General Engine Specifications
Description Specification Limit
General
Type In-line, Double Over Head
Camshaft
Number of cylinders 4
Bore 6.5 mm (3.0118 in)
Stroke 8 mm (3.4252 in)
Total displacement 1599 cc (9 .54 cu.in)
Compression ratio 10
Firing order 1-3-4-2
Valve timing
Intake valve
Opens (BTDC) 5°
Closes (ABDC) 35°
Exhaust valve
Opens (BBDC) 43°
Closes (ATDC) 5°
Valve overlap 10°
Cylin er hea
Flatness of cylinder head surface Max. 0.03 mm (0.0012 in.) 0.1 mm (0.0039 in.)
Flatness of mainfold mounting
surface
0.15 mm (0.0059 in.) 0.2 mm (0.008 in.)
Oversize rework dimension of
valve seat hole Intake
0.3 mm (0.012 in.) O.S. 30. ~ 30. 21 mm (1.208 ~
1.2095 in.)
0.6 mm (0.024 in.) O.S. 31.0 ~ 31.021 mm (1.2205 ~
1.2213 in.)
Exhaust
0.3 mm (0.012 in.) O.S. 2 .3 ~ 2 .321 mm (1.0 48 ~
1.0 56 in.)
0.6 mm (0.024 in.) O.S 2 .6 ~ 2 .621 mm (1.0866 ~
1.08 4 in.)
Oversize rework imensions of
valve
2004 Hyundai Accent
2004 ENGINES 1.6L 4-Cylinder - Accent
2004 Hyundai Accent
2004 ENGINES 1.6L 4-Cylinder - Accent
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Guide hole
0.05 mm (0.002 in.) O.S. 11.05 ~ 11.068 mm (0.435 ~
0.435 in.)
0.25 mm (0.010 in.) O.S. 11.25 ~ 11.268 mm (0.443 ~
0.4436 in.)
0.50 mm (0.020 in.) O.S. 11.50 ~ 11.518 mm (0.453 ~
0.4535 in.)
Camshaft
Cam lobe height
Intake 43.4484 mm (1. 106 in.) 42.9484 mm (1.6909 in.)
Exhaust 43.8489 mm (1. 263 in.) 43.3489 mm (1. .66 in.)
Journal O.D Ø2 mm (1.0630 in.)
Bearing oil clearance 0.035 ~ 0.0 2 mm (0.0014 ~
0.0028 in.)
End play 0.1 ~ 0.2 mm (0.004 ~ 0.008 in.)
Valve
Valve length
Intake 91. mm (3.6102 in.)
Exhaust 92.3 mm (3.6339 in.)
Stem O.D.
Intake 5.955 ~ 5.9 mm (0.2344 ~ 0.2350
in.)
Exhaust 5.935 ~ 5.95 mm (0.233 ~ 0.2343
in.)
Face angle thickness of valve head
(Margin)
Intake 1.1 mm (0.0433 in.) 0.8 mm (0.031 in.)
Exhaust 1.3 mm (0.0512 in.) 1.0 mm (0.039 in.)
Valve stem to valve guide
clearance
Intake 0.03 ~ 0.06 mm (0.0012 ~ 0.0024
in.) 0.10 mm (0.0039 in.)
Exhaust 0.05 ~ 0.08 mm (0.0020 ~ 0.0031
in.) 0.15 mm (0.0059 in.)
Valve gui e
Installed dimension O.D.
Intake 12.8 mm (0.504 in.)
Exhaust 12.8 mm (0.504 in.)
Service size 0.05, 0.25, 0.50 mm (0.002, 0.010,
0.020 in.) oversize
Valve seat
Width of seat contact
Intake 0.8 ~ 1.2 mm (0.031 ~ 0.04 in.)
Exhaust 1.3 ~ 1. mm (0.051 ~ 0.066 in.)
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Seat angle 45°
Oversize 0.3, 0.6 mm (0.012, 0.024 in.)
oversize
Valve spring
Free length 44.00 mm (1. 323 in.)
Load
21.6kg/35 mm (4 .6lb/1.3 80 in.)
45.1 kg/2 .2 mm (99.4lb/1.0 1
in.)
Squareness 1.5° or less
Cylin er block
Cylinder bore 6.50 ~ 6.53 mm (3.0118 ~
3.0130 in.)
Out-of-round and taper of cylinder
bore
Clearance with piston
Less than 0.01 mm (0.0004 in.)
0.025 ~ 0.045 mm (0.0009 -
0.001 in.)
Piston
O.D. 6.465 ~ 6.495 mm (3.0104 ~
3.0116 in.)
Service size 0.25 mm (0.010 in.) oversize
Piston ring
Side clearance
No. 1 0.04 ~ 0.085 mm (0.0015 ~ 0.0033
in.) 0.1 mm (0.004 in.)
No. 2 0.04 ~ 0.085 mm (0.0015 ~ 0.0033
in.) 0.1 mm (0.004 in.)
Endgap
No. 1 0.15 ~ 0.30 mm (0.0059 ~ 0.012
in.) 1.0 mm (0.039 in.)
No. 2 0.30 ~ 0.45 mm (0.012 ~ 0.01
in.) 1.0 mm (0.039 in.)
Oil ring side rail 0.2 ~ 0. mm (0.00 8 ~ 0.02 5
in.) 1.0 mm (0.039 in.)
Service size 0.25 mm (0.010 in.) oversize
Connecting ro
Bend 0.05 mm (0.0020 in.) or less
Twist 0.1 mm (0.0039 in.) or less
Connecting rod big end to
crankshaft side clearance
0.100-0.250 mm (0.0039-0.0098
in.) 0.4 mm (0.015 in.)
Connecting rod bearing oil
clearance
0.018-0.036 mm (0.000 -0.0014
in.)
Undersize 0.25, 0.50, 0. 5 mm (0.010, 0.020,
0.030 in.)
Crankshaft
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Pin O.D. 45 mm (1. in.)
Journal O.D. 50 mm (1.9 in.)
Berid 0.03 mm (0.0012 in.) or less
Out- of- round, taper of journal
and pin 0.005 mm (0.0002 in.) or less
End play 0.05 - 0.1 5 mm (0.0019 - 0.0068
in.)
Un ersize rework imension of
pin
0.25 mm (0.010 in.) 44. 25 ~ 44. 4 mm (1. 608 ~
1. 614 in.)
0.50 mm (0.020 in.) 44.4 5 ~ 44.49 mm (1. 509 ~
1. 516 in.)
0. 5 mm (0.030 in.) 44.225 ~ 44.24 mm (1. 411 ~
1. 41 in.)
Un ersize rework imension of
journal
0.25 mm (0.010 in.) 49. 2 ~ 49. 42 mm (1.95 ~
1.9583 in.)
0.50 mm (0.020 in.) 49.4 ~ 49.492 mm (1.94 9 ~
1.9485 in.)
0. 5 mm (0.030 in.) 49.22 ~ 49.242 mm (1.9380 ~
1.9386 in.)
Flywheel
Runout 0.1 mm (0.0039 in.) 0.13 mm (0.0051 in.)
Oil pump
Clearance between outer
circumference and front case
(body clearance)
0.12 ~ 0.18 mm (0.004 ~ 0.00 0
in.)
Front case tip clearance 0.025 ~ 0.069 mm (0.001 ~ 0.002
in.)
Side clearance
Inner gear 0.04 ~ 0.085 mm (0.0016 ~ 0.0033
in.)
Outer gear 0.04 ~ 0.09 mm (0.0016 ~ 0.0035
in.)
Engine oil pressure
Engine at idle [Oil temperature is
90 to 100°C (194 to 215°F)] 14 KPa (1.5 kg/ cm2 , 21.33 psi)
Relief spring
Free height 46.6 mm (1.8346 in.)
Load 6.1kg at 40.1 mm (13.42lb/1.5 8
in.)
Cooling metho Water-cooled, pressurized, forced
circulation with electrical fan
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TIGHTENING TORQUE
TORQUE SPECIFICATIONS
Coolant
Quantity 6.5 liter
Radiator
Type Pressurized corrugated fin type
Ra iator cap
Main valve opening pressure 81.4 ~ 108 kpa (11.8 ~ 15.6 psi.,
0.83 ~ 1.1 kg/cm2 )
Vacuum valve opening pressure -6.86 kpa (-1.00 psi, -0.0 kg/cm2
or less
Coolant pump Centrifugal type impeller
Thermostat
Type Wax pellet type with jiggle valve
Valve opening temperature 82°C (180°F)
Full-opening temperature 95°C (203°F)
Engine coolant temperature
sensor
Type Heat-sensitive thermistor type
Resistance
2.31 ~ 2.59kohms at 20°C(68°F)
146.9 ~ 14 .3 ohms at 110°C(230°
F)
Air cleaner
Type Dry type
Element Un woven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
NOTE O.D. = Outer Diameter
I.D. = Inner Diameter
O.S. = Oversize Diameter
U.S. = Undersize Diameter
Application Ft Lbs. (N.m)
Alternator Brace Bolt 15-21 (20-28)
Alternator Support Bolt & Nut 15-18 (20-25)
Camshaft Sprocket Bolt 59- 4 (80-100)
Connecting Rod Cap Nut 24-26 (32-35)
Coolant Temperature Sensor 18-22 (25-30)
Crankshaft Bearing Cap Bolt 41-44 (55-60)
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Crankshaft Pulley Bolt 103-111 (140-150)
Cylinder Head Bolts (1)
Step 1 22 (30)
Step 2 Tighten An Additional
90 Degrees
Step 3 Release All Bolts
Step 4 22 (30)
Step 5 Tighten An Additional
90 Degrees
Driveplate/Flywheel Bolts 96-103 (130-140)
Engine Mounting Components
Front Roll Stopper Bracket-To-Sub Frame 22-30 (30-40)
Front Roll Stopper Insulator Bolt 33-44 (45-60)
Rear Roll Stopper Bracket Subframe Bolts 22-30 (30-40)
Rear Roll Stopper Insulator Nut 33-44 (45-60)
Right Mounting Insulator (Large) Bolt 66-81 (90-110)
Right Mounting Insulator (Small) Nut 3 -48 (50-65)
Transaxle Insulator Bracket-To-Side Member Nut 22-30 (30-40)
Transaxle Mount Insulator Bolt 66-81 (90-110)
Engine Support Bracket Stay 33-41 (45-55)
Exhaust Components
Exhaust Manifold Cover-To-Exhaust Manifold Bolts 11-15 (15-20)
Exhaust Manifold Nut 18-22 (25-30)
Exhaust Pipe-To-Catalytic Converter 30-40 (40-60)
Exhaust Pipe-To-Exhaust Manifold Nut 22-30 (30-40)
Front Exhaust Bracket Bolts 22-30 (30-40)
Front Case Bolt 15-20 (20-2 )
Front Engine Support Bracket Bolt & Nut 33-41 (45-55)
Intake Manifold Bolts & Nuts 11-15 (15-20)
Oil Filter 9-12 (12-16)
Oil Pan Drain Plug 30-33 (40-45)
Oil Screen Bolts 11-16 (15-22)
Oxygen Sensor 3 -44 (50-60)
Rear Plate Bolt 24-26 (32-35)
Surge Tank Stay-To-Cylinder Block Bolts 13-18 (18-25)
Thermostat Housing Bolt 11-15 (15-20)
Throttle Body-To-Surge Tank Bolts 11-15 (15-20)
Timing Belt Idler Bolt 32-41 (43-55)
Timing Belt Tensioner Bolt 15-20 (20-2 )
INCH Lbs. (N.m)
Air Cleaner Body Mounting Bolts 1-89 (8-10)
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Fig. 1: I entifying Cylin er Hea Tightening Sequence
Courtesy of HYUNDAI MOTOR CO.
SERVICE STANDARD
Alternator Lock Bolt 106-133 (12-15)
Camshaft Bearing Cap Bolts 106-124 (12-14)
Coolant Pump Bolt 106-133 (12-15)
Coolant Pump Pulley Bolt 1-89 (8-10)
Cylinder Head Cover Bolts 1-89 (8-10)
Oil Pan Bolts 88-106 (10-12)
Oil Pressure Switch 115-133 (13-15)
Resonator Mounting Bolt 35-53 (4-6)
Timing Belt Cover Bolt 1-88 (8-10)
(1) Tighten cylinder head bolts in sequence. See Fig. 1.
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Fig. 2: I entifying Engine Coolant & Mixture
Courtesy of HYUNDAI MOTOR CO.
CHECKING ENGINE OIL
1. Position the vehicle on a level surface.
2. Warm up the engine.
3. Turn off the engine, and wait 2 or 3 minutes, then check the oil level.
4. Check that the engine oil level is within the level range indicated on the oil dipstick if the oil level is
found to have fallen to the lower limit (the L mark), refill to the "F" mark.
Fig. 3: I entifying Engine Oil Dipstick
Courtesy of HYUNDAI MOTOR CO.
5. Check that the oil is not dirty or contaminated with coolant or gasoline, and that it has the proper
viscosity.
CHANGING ENGINE OIL
1. Run the engine until it reaches normal operating temperature.
2. Turn off the engine
3. Remove the oil filler cap and the drain plug (on the oil pan). Drain the engine oil.
NOTE If a vehicle has been out of service for a prolonged period of time, warm
up the engine for approximately 20 minutes.
NOTE When refilling, use the same type of engine oil.
CAUTION Be careful not to burn yourself, as the engine oil is hot.
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Fig. 4: Locating Engine Oil Drain Plug
Courtesy of HYUNDAI MOTOR CO.
4. Install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug: 40 ~ 45 Nm (400 ~ 450 kg.cm, 30 ~ 33 lb.ft)
5. Fill the crankcase with fresh engine oil through the oil filler cap opening.
Drain and Refill Without oil filter:
3.0 liter (3.1 U.S.qts, 2.64 Imp.qts)
Draining and Refill With oil filter:
3.3 liter (3.48 U.S.qts, 2.64 Imp.qts)
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6. Install the oil filler cap.
. Start and run the engine.
8. Turn off the engine and then check the oil level. Add oil if necessary.
FILTER SELECTION
All Hyundai engines are equipped with a high quality, disposable oil filter. This filter is recommended as a
replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality
filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter
is completely removed from the contact surface on the engine block before installing the new filter.
Fig. 5: Locating Engine Oil Filter Part Number
Courtesy of HYUNDAI MOTOR CO.
PROCEDURE FOR REPLACING THE OIL FILTER
CAUTION Be careful not to burn yourself, as the engine and engine oil are hot.
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1. Use a filter wrench to remove the oil filter.
Fig. 6: Locating Engine Oil Filter
Courtesy of HYUNDAI MOTOR CO.
2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber
gasket.
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Fig. 7: Removing Engine Oil Filter & Applying Engine Oil To New Filter
Courtesy of HYUNDAI MOTOR CO.
3. Tighten the oil filter to the specified torque.
Tightening torque
Oil filter: 12 ~ 16 Nm (120 ~ 160 kg.cm, 9 ~ 12 lb.ft)
4. Run the engine to check for engine oil leaks.
5. After turning off the engine, check the oil level and add oil as necessary.
SELECTION OF ENGINE OIL
Recommended API classification: SH OR ABOVE
Recommended SAE viscosity grades:
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Fig. 8: I entifying Recommen e SAE Viscosity Gra es
Courtesy of HYUNDAI MOTOR CO.
1. Satisfy the requirements of the API classification.
2. Have proper SAE grade number for expected ambient temperature range.
Lubricant that does not have both an SAE grade number and an API service classification on the container
should not be used.
CHECKING COOLANT LEAK
1. Wait until the engine is cool, then carefully remove the radiator cap.
2. Confirm that the coolant level is up to the filler neck.
3. Install a radiator cap tester to the radiator filler neck and apply 140 KPa (1.4 kg/cm2 , 20psi) pressure.
NOTE For best performance and maximum protection of all types of operation, select
only those lubricants which
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Hold it for two minutes in that condition, while checking for leakage from the radiator, hoses or
connections.
4. If there is leakage, repair or replace with the appropriate part.
Fig. 9: Testing Coolant System for Leak
Courtesy of HYUNDAI MOTOR CO.
RADIATOR CAP PRESSURE TEST
1. Remove the radiator cap, wet its seal with engine coolant, then install it on the tester.
2.
Increase the pressure until the gauge stops moving.
NOTE 1. Radiator coolant may be extremely hot. Do not open the system
because hot, or scalding water could gush out causing personal
injury. Allow the vehicle to cool before servicing this system.
2. Be sure to clean away any moisture from the places checked
completely.
3. When the tester is removed, be careful not to spill any coolant from
it.
4. Be careful, when installing and removing the tester and when testing,
not to deform the filler neck of the radiator.
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Main valve opening pressure:
83 ~ 110 kPa (0.83 ~ 1.1 kg/cm2 , 12 ~ 16 psi)
Vacuum valve opening pressure:
- kPa (-0.0 kg/cm2 , -1.0 psi)
3. Check that the pressure level is maintained at or above the limit.
4. Replace the radiator cap if the reading does not remain at or above the limit.
Fig. 10: Pressure Testing Ra iator Cap
Courtesy of HYUNDAI MOTOR CO.
SPECIFIC GRAVITY TEST
NOTE Be sure that the cap is clean before testing, since rust or other foreign
material on the cap seal will cause an incorrect reading.
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1. Measure the specific gravity of the coolant with a hydrometer.
Fig. 11: Using Hy rometer To Test Coolant Gravity
Courtesy of HYUNDAI MOTOR CO.
2. Measure the coolant temperature and calculate the concentration from the relation between the specific
gravity and temperature, using the following table for reference.
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Fig. 12: Coolant Concentration & Specific Gravity Specifications
Courtesy of HYUNDAI MOTOR CO.
Example
The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant
temperature of 20°C (68°F)
RECOMMENDED COOLANT
Fig. 13: Recommen e Coolant Mixtures
Courtesy of HYUNDAI MOTOR CO.
CHANGING ENGINE COOLANT
1. Slide the heater temperature control lever to maximum heat. Make sure the engine and radiator are cool to
the touch.
2. Remove the radiator cap.
3. Loosen the drain plug, and drain the coolant.
CAUTION If the concentration of the coolant is below 30%, its anti-corrosion
properties will be adversely affected.
If the concentration is above 60%, both the anti-freeze and engine
cooling property will decrease, affecting the engine adversely. For
these reasons, be sure to maintain the concentration level within the
specified range.
Do not use together with another brands product.
CAUTION When pouring engine coolant, be sure to shut the relay box lid and not to
let coolant spill on electrical parts or the paint. If any coolant spills, rinse it
off immediately.
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Fig. 14: Locating Coolant Drain Plug
Courtesy of HYUNDAI MOTOR CO.
4. Tighten the radiator drain plug securely.
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. Pour coolant into the radiator up to the base of the filler neck, and install the radiator cap loosely.
. Start the engine and let it run until it warms up (the radiator fan comes on at least twice).
8. Turn off the engine.
Check the level in the radiator, add coolant if needed.
9. Put the radiator cap on tightly, then run the engine again and check for leaks.
CHECKING COMPRESSION PRESSURE
1. Before checking engine compression, check the engine oil level. Also check that the starter motor and
battery are all in normal operating condition.
2.
Check the DTC and note it. Use the scan tool to clear the ECM'S memory.
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3. Start the engine and wait until engine coolant temperature reaches 80 ~ 95°C (1 6 ~ 205°F).
4. Disconnect the fuel pump connector.
5. Turn off engine and disconnect the spark plug cables.
Fig. 15: Removing Spark Plug Cable From Cylin er Hea
Courtesy of HYUNDAI MOTOR CO.
6. Remove the spark plugs.
. Disconnect the I.G. connector.
8. Crank the engine to remove any foreign material in the cylinders.
9.
Insert the compression gauge into the spark plug hole.
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Fig. 16: Inserting Compression Gauge Into Spark Plug Hole
Courtesy of HYUNDAI MOTOR CO.
10. Depress the accelerator pedal to open the throttle fully.
11. Crank the engine and read the gauge.
Standard value: 1500kpa (15Kg/cm2 , 218 psi)
Limit: 1400kpa (14Kg/cm2 , 203 psi)
12. Repeat steps 9 to 11 over all cylinders, ensuring that the pressure differential for each of the cylinders is
within the specified limit.
Limit
Max 100 kpa (1.0 kg/cm2 , 14 psi) between cylinders
13. If a cylinder's compression or pressure differential is outside the specification, add a small amount of oil
through the spark plug hole, and repeat steps 9 to 12.
1. If the addition of oil makes the compression to rise, it is likely that there may be wear between the
piston ring and cylinder wall.
2. If compression remains the same, valve seizure, poor valve seating or a compression leak from the
cylinder head gasket are all possible causes.
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