ENGINE
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GENERAL
.........................................
2
ENGINE MOUNTING .................................
21
ENGINE AND TRANSMISSION ASSEMBLY
..............
26
TIMING BELT TRAIN
...................................
30
ROCKER ARMS AND ROCKER SHAFT ...................
36
CAMSHAFT .......................................... 38
CYLINDER HEAD
....................................
42
VALVE AND VALVE SPRINGS
........................
46
JET VALVE .................................... 52
FRONT CASE, OIL PUMP
.............................
56
PISTON AND CONNECTING ROD
.......................
61
CRANKSHAFT
...............................

66
FLYWHEEL
....................................... 69
CYLlNDER BLOCK
............................. 70
OIL PRESSURE SWITCH
............................... 72
GENERAL
GENERAL
SPECIFICATIONS
Description
Standard
Limit
General
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Firing order
Basic ignition timing
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)
Jet valve

Opens (BTDC)
Closes (ABDC)
Valve overlap
Intake valve duration
Exhaust valve duration
Jet valve duration
Compression pressure
15°
53°
53°
15°
Valve clearance-Hot engine
Intake valve
Exhaust valve
Jet valve
Cylinder head
Warpage of lower face of head
Clearance with camshaft
Oversize rework dimension of valve seat hole
Intake
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
Exhaust
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
Oversize rework of valve guide hole
(both intake and exhaust)
0.05 mm (0.002 in.)
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)

In-line OHV, OHC
4
75.5 mm (2.97 in.)
82 mm (3.23 in.)
1,468 cc (89.6 cu.in.)
9.4
1-3-4-2
Refer to emission control
information label on car
15°
53°
30°
248°
248°
248°
1.12 MPa (11.4 kg/cm
2
,
164 psi)/250 rpm
0.15 mm (0.006 in.)
0.25 mm (0.010 in.)
0.25 mm (0.010 in.)
Within 0.05 mm (0.002 in.)
0.05-0.09 mm (0.002-0.0035 in.)
0.1 mm (0.004 in.)
39.3-39.325 mm (1.5472-1.5482 in.)
39.6-39.625 mm (1.5590-1.5600in.)
34.3-34.325 mm (1.3504-1.3534 in.)
34.6-34.625 mm (1.3622-1.3632 in.)
13.05-13.068 mm (0.5135-0.5145 in.)

13.25-13.268 mm (0.5216-0.5224 in.)
13.50-13.518 mm (0.5315-0.5323 in.)
20-2
GENERAL
Description
Standard
Limit
Camshaft
Height of cam lobe
Intake
Exhaust
End play
Valve
Stem O.D.
Intake
Exhaust
Thickness of valve head (Margin)
Intake
Exhaust
Clearance with valve guide
Intake
Exhaust
Valve guide
Installed dimension
Oversize
Valve seat insert
Width of seat contact
Seat angle
Oversize
Valve spring

Free length
Load
Installed height
Squareness
Jet valve
Stem O.D.
Seat angle
Jet valve spring
Free length
Load
Cylinder block
Cylinder bore
Out-of-roundness and taper of cylinder bore
Clearance with piston
Piston
O.D.
Oversize
38.1 mm (1.5000 in.) -0.5 mm (-0.020 in.)
38.2 mm (1.5039 in.)
-0.5 mm (-0.020 in.)
0.05-0.20 mm (0.002-0.008 in.)
6.6 mm (0.26 in.)
6.6 mm (0.26 in.)
1.0 mm (0.039 in.) 0.7 mm (0.028 in.)
1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
0.03-0.06 mm (0.0012-0.0024 in.)
0.10 mm (0.004 in.)
0.05-0.09 mm (0.0020-0.0035 in.) 0.15 mm (0.006 in.)
13.7-14.3 mm (0.5394-0.5630 in.)
0.05 mm, 0.25 mm, 0.50 mm

(0.002 in., 0.010 in., 0.020 in.)
0.9-1.3 mm (0.035 in., 0.024 in.)
45°
0.3 mm, 0.6 mm (0.012 in., 0.024 in.)
44.6 mm (1.756 in.)
24 kg/27.3 mm (53 lb./1.469 in.)
36 mm (1.417 in.)
1.5° or less
4.300 mm (0.1693 in.)
45°
-1.0 mm (-0.039 in.)
+1 mm (+0.039 in.)
3°
29.60 mm (1.1654 in.)
3.5 kg/21.5 mm (5.5 lb/0.846 in.)
75.5 mm (2.972 in.)
Within 0.02 mm (0.0008 in.)
0.02-0.04 mm (0.0008-0.0016 in.)
75.5 mm (2.972 in.)
0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
(0.010 in., 0.020 in., 0.030 in., 0.039 in.)
20-3
GENERAL
Description
Standard
Limit
Piston ring
Side clearance
No. 1
No. 2

End gap
No. 1 and No. 2
Oil ring
Oversize
Connecting rod
Bend
Twist
Side clearance
Connecting rod bearing
Oil clearance
Undersize
Crankshaft
Pin O.D.
Journal O.D.
Bend
Out-of-roundness, taper of journal and pin
End play
Undersize rework dimension of pin
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
0.75 mm (0.030 in.)
Undersize rework dimension of journal
0.25 mm (0.010 in.)
0.50 mm (0.020 in.)
0.75 mm (0.030 in.)
Flywheel
Out-of-roundness
Oil pump
Outer gear
Clearance between outer circumference

and front case
Clearance between addendum and crescent
End play
Inner gear
Clearance between addendum and crescent
End play
Relief spring
Free height
Load
0.03-0.07 mm (0.0012-0.0028 in.) 0.15 mm (0.006 in.)
0.02-0.06 mm (0.0008-0.0024 in.) 0.12 mm (0.005 in.)
0.20-0.35 mm (0.008-0.0014 in.) 0.10 mm (0.039 in.)
0.20-0.70 mm (0.008-0.028 in.)
0.10 mm (0.039 in.)
0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
(0.010 in., 0.020 in., 0.030 in., 0.039 in.)
0.05 mm (0.0020 in.) or less
0.10 mm (0.0039 in.) or less
0.10-0.25 mm (0.004-0.010 in.)
0.01-0.06 mm (0.0004-0.0024 in.)
0.25 mm, 0.50 mm, 0.75 mm
(0.01 in., 0.02 in., 0.03 in.)
42 mm (1.6535 in.)
48 mm (1.8898 in.)
Within 0.03 mm (0.0012 in.)
Within 0.01 mm (0.0004 in.)
0.05-0.18 mm (0.002-0.007 in.)
41.735-41.750 mm (1.6431-1.6437 in.)
41.485-41.500 mm (1.6333-1.6339 in.)
41.235-41.250 mm (1.6234-1.6240 in.)

47.735-47.750 mm (1.8793-1.8799 in.)
47.485-47.500 mm (1.8695-1.8701 in.)
47.235-47.250 mm (1.8596-1.8602 in.)
Within 0.13 mm (0.005 in.)
0.1-0.2 mm (0.0039-0.0079 in.)
0.22-0.34 mm (0.0087-0.0134 in.)
0.04-0.10 mm (0.0016-0.0039 in.)
0.21-0.32 mm (0.0083-0.0126 in.)
0.04-0.10 mm (0.0016-0.0039 in.)
47 mm (1.850 in.)
4.3 kg/40 mm (9.5 lb/1.575 in.)
20-4
GENERAL
SERVICE STANDARD
Standard value
Belt deflection
Clearance between timing belt and seal line
Piston pin press in load
Flywheel runout
Oil pressure gauge unit
Current flow
at 0 kPa (0 psi, 0 kg/cm
2
)
at 392 kPa (57 psi, 4 kg/cm
2
)
at 785 kPa (114 psi, 8 kg/cm
2
)

7-9 mm (0.28-0.35 in.)
Approx. 14 mm (0.55 in.)
4,900-14,700 N (1,102-3,306 lb)
0.1 mm (0.004 in.) max.
0 mA
84 mA
110 mA
TIGHTENING TORQUE
Nm
kg.cm
Ib.ft
Cylinder Block
Front engine support bracket bolt
Front roll stopper bracket bolt
Rear roll stopper bracket bolt
Left engine support bracket bolt
Oil pressure switch
Cylinder Head
Cylinder head bolt-cold engine
-hot engine
Intake/exhaust manifold bolt or nut
Rocker cover bolt
Rocker arm shaft bolt
Camshaft bolt
Rear plate bolt
Jet valve
Main Moving
Connecting rod cap nut
Crankshaft bearing cap
Fly wheel (manual transmission) bolt

Drive plate (automatic transmission) bolt
Timing Belt
Crankshaft pulley bolt
Crankshaft sprocket bolt
Camshaft sprocket bolt
Timing belt tensioner bolt
Timing belt cover bolt
Front case bolt
59-78
600-800
43-58
54-69
550-700
40-51
29-39
300-400
22-29
59-78
600-800 43-58
15-21
150-210
11-15
69-74
700-750
51-54
78-83
800-850
58-61
16-19
160-190

12-14
1.5-2.0
15-20
1.1-1.4
20-26
200-270
14-20
20-26
200-270
14-20
7.8-9.8
80-100
5.8-7.2
18-22
180-220
13-16
31-34
320-350
49-53
500-540
127-137
1,300-1,400
127-137
1,300-1,400
12-15
122-150
8.7-11
69-98
700-1,000
51-72

64-74
650-750
47-54
20-26
200-270
14-20
9.8-12
100-120
7.2-8.7
12-15
120-150
8.7-11
23-25
36-39
94-101
94-101
20-5
GENERAL
Nm kg.cm Ib.ft
Engine Mounting
Left mounting insulator (large) nut
59-78 600-800 43-58
Left mounting insulator (small) nut
29-39 300-400
22-29
Left mounting bracket to engine nut
49-64
500-650 36-47
Transmission mount insulator bolt
59-78 600-800 43-58

Transmission insulator bracket to side member bolt
29-39 300-400
22-29
Transmission mount bracket to automatic transmission nut
59-78 600-800
43-58
Rear roll insulator bolt
29-39 300-400
22-29
Rear roll stopper bracket to crossmember bolt
29-39 300-400
22-29
Front roll rod upper bolt
29-39 300-400
22-29
Front roll rod lower bolt
54-69 550-700
40-51
SELECTION OF LUBRICANTS
Engine Oil
Temperature range
anticipated before
next oil change
°C
°F
16
60
0
32
-23

-10
Recommended SAE viscosity number
*1. Restricted by driving condition and dealing area.
*2. Not recommended for sustained high speed vehicle operation.
For best performance and for maximum protection of all engines for all types of operation, select only those lubricants
which:
1. Conform to the requirements of API classification.
2. Have proper SAE grade number for expected ambient temperature range.
Lubricants which do not have both an SAE grade number and an API service classification on the container
should
not
be used.
20-6
GENERAL
SELECTION OF THE COOLANT
Coolant
RELATION BETWEEN ANTIFREEZE CONCENTRATION AND SPECIFIC GRAVITY
The following table is applicable only to the specified HIGH QUALITY ETHYLENE GLYCOL (ANTIFREEZE) COOLANT.
Coolant temperature °C (°F) and specific gravity
Freezing
Safe operating
Coolant
temperature temperature
concentration
10 (50) 20 (68)
30 (86)
40 (104) 50 (122) °C (°F) °C (°F)
(Specific volume)
1.054 1.050
1.046

1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058
1.054
1.049 1.044 -22 (-4) -15 (5) 35%
1.071
1.067
1.062
1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074
1.069
1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082
1.076
1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090
1.084
1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098
1.092
1.084 1.076 -50 (-58) -45 (-49) 60%
Example
The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at the coolant tempera-
ture of 20°C (68°F).
20-7
GENERAL
SPECIAL TOOLS
Tool
(Number and name)
09214-21000
Crank shaft front oil seal in-

staller
09214-21100
Crank shaft front oil seal guide
Illustration
Use
Installation of the crank shaft front oil seal
(use with 09214-21100)
Installation of the crank shaft front oil seal
(use with 09214-21000)
09216-21000
Removal and installation of the front roll
Mount bushing remover and
rod upper bushing (use with 09216-21100
installer arbor
and 09216-21000)
09216-21100
Mount bushing remover and
installer base
1. Removal and installation of the front roll
rod upper bushing (use with 09216-
21000 and 09216-21200)
2. Removal and installation of the rear roll
rod upper bushing (use with 09216-
21000 and 09216-21700)
09216-21200
Mount bushing remover and
installer ring
Removal and installation of the front roll
rod upper bushing (use with 09216-21000
and 09216-21100)

09216-21300
Mount bushing remover and
installer base
Removal and installation of the front roll
rod lower bushing (use with 09216-21400
and 09216-21500)
09216-21400
Mount bushing remover and
installer arbor
Removal and installation of the front roll
rod lower bushing (use with 09216-21300
and 09216-21500)
09216-21500
Mount bushing remover and
installer ring
Removal and installation of the front roll
rod lower bushing (use with 09216-21300
and 09216-21400)
20-8
GENERAL
Tool
(Number and name)
09216-21600
Mount bushing remover and
installer arbor
Illustration
Use
Removal and installation of the rear roll
stopper bushing (use with 09216-21100
and 09216-21700)

09216-21700
Mount bushing remover and
installer ring
Removal and installation of the rear roll
stopper bushing (use with 09216-21100
and 09216-21600)
09221-11000
Cylinder head bolt wrench
Removal and tightening of the cylinder
head bolt
09221-21000
Camshaft oil seal installer
Installation of the camshaft oil seal (use
with 09221-21100)
09221-21100
Camshaft oil seal guide
Using as a guide when pressing in the
camshaft oil seal (use with 09221-21000)
09222-21001
Valve spring compressor
Removal and installation of the inlet or
exhaust valve
09222-21100
Valve stem oil seal installer
09222-21200
Valve guide installer
Installation of the valve stem oil seal
Removal and installation of the valve guide
20-9
GENERAL

20-10
GENERAL
Tool
(Number and name)
Illustration
Use
09391-21101
Harness connector for FBC
Inspection for FBC system (use with 09341-
21000)
20-11
GENERAL
TROUBLESHOOTING
Symptom
Misalignment of suspension
Vehicle will not move
Noise occurs when accelerating
or decelerating
Body vibration
Loose transmission mount
Probable cause
Bent engine mount bracket
Deformed engine roll stopper and roll bracket
Broken insulator in engine roll stopper
Deformed engine mount pipe
Deformed transmission mount bracket
Broken engine front mount bracket
Broken engine rear mount bracket
Broken rod in engine mount bracket
Broken transmission mount bracket

Loose engine front mount bracket
Loose engine rear mount bracket
Loose engine roll stopper bracket
Loose transmission mount bracket
Broken engine mount insulator
Broken transmission mount insulator
Loose bolt tightening transmission mount
bracket
Remedy
Replace bracket
Replace bracket
Replace insulator
Replace pipe
Replace bracket
Replace bracket
Replace bracket
Replace bracket or rod
Replace bracket
Retighten bolt
Retighten bolt
Retighten bolt
Retighten bolt
Replace insulator
Replace insulator
Reposition mounting
parts
20-12
GENERAL
20-13
GENERAL

20-14
GENERAL
RETORQUING OF CYLINDER HEAD BOLTS
1.
When cylinder head bolts are retorqued, first slightly loosen and
then tighten to specified torque.
2. Be sure to follow the specific torquing sequence.
3. After cylinder head bolts have been tightened to specified
torque, run engine until normal operating temperature is
reached, allow it to cool down, and then retorque bolts to speci-
fication for best results.
Tightening torque
Cold engine . . . . . . .
69-73 Nm (704-745 kg.cm, 51-54 Ib.ft)
Hot engine . . . . . . . 79-83 Nm (806-847 kg.cm, 58-61 Ib.ft)
ENGINE OIL LEVEL GAUGE
1. The oil level gauge is located on the forward side of the engine.
2. Maintain engine oil level within the marking lines on the oil
level gauge. The oil level in the oil pan may read at the “MAX”
mark line (upper limit) after the engine has been standing for
several hours, but when the engine is started the oil level will
drop somewhat due to filling of oil passage, etc.
3. When the oil level is at or below the “MIN” mark line (lower
limit) on the level gauge, add 1 liter (1 U.S. quart). The oil should
never be allowed to remain below the lower limit.
CAUTION:
Do not overfill crankcase. This will cause oil aeration and loss
.
of oil pressure.
OIL FILTER

Filter Selection
All Hyundai Motor Company engines are equipped with high
quality, full flow throwaway oil filter. This filter is recommended
as a replacement filter in service on all vehicles.
The quality of replacement filter varies considerably. Only high
quality filter should be used to assure most efficient service.
Replacing Oil Filter
1. Use filter wrench or the like to remove oil filter. Clean the
mounting surface on the block carefully.
2. Apply a thin film of engine oil to the surface of the new gasket
before screwing filter on.
3. Then tighten filter enough by hand.
4. Start and run engine and check for engine oil leaks.
5. After stopping engine, check oil level and replenish as neces-
sary.
GENERAL
TIMING BELT AND TIMING BELT TENSIONER INSTA-
LLING PROCEDURE
1. Assemble rocker arm adjusting screw in tentative state.
Then screw must protrude within 1 mm (0.04 in.)
NOTE
(a) Take special care not screw to be below arm end, other-
wise valve stem would rust thread part.
(b) In case of protruding too much, tension of belt would be
excessive.
2. Tentatively fasten timing belt tensioner at such position as to
place it’s pulley nearest to water pump (pulley may touch water
pump body)
3. After installing flange, crankshaft sprocket and camshaft
sprocket match timing mark of each sprocket as shown in

illustration.
As a result of this, get piston in No. 1 cylinder at top dead center
on compression stroke.
CAUTION
(a)
Take special care of installing direction of flange. (Cham-
fered part shows front of engine).
(b)
When installing camshaft sprocket, make sure that knock
pin and camshaft fits small hole in pulley.
20-16
GENERAL
NOTE
Allow tensioner to remain in assemble state must be installed
temporarily as follows.
o Tentatively tighten tensioner at position as shown in illus-
tration, in state that one extended end of spring tensioner
is assembled to bend of tensioner bracket as imaginary
line (wheel spring tensioner is inoperative and not loaded).
o Then set extended end of tensioner spring at front case
with drive etc.
4. Install timing belt so as not to give slack to tension side. Then
make sure all timing marks are at correct position respectively
with tension side in strained state by applying force to camshaft
sprocket in reversing (counterclockwise) direction.
20-17
GENERAL
TIMING BELT TENSION ADJUSTMENT PROCE-
DURE
If any unusual noise is caused by improperly adjusted timing

belt tension, use the following procedure to readjust the
tension.
1. Remove timing belt upper cover and water pump pulley.
2. Check the belt for cracking, peeling or other damage. Be sure to
carefully check the entire length of the belt.
3. Set the engine so that the No. 1 cylinder is at the compression
top dead center. In other words, align the timing mark on the
camshaft sprocket with that on the cylinder head.
Note that the crankshaft should be turned clockwise, not in
reverse. Turning the crankshaft counterclockwise will cause
the tension to become improperly adjusted.
4. Remove the timing belt lower cover.
5. Loosen the tensioner mounting bolts 1 and 2 in that order as
shown to give the timing belt only spring tension.
6. Check the belt to ensure that it is not out of position.
20-18
GENERAL
7. Tighten the tensioner attaching bolts 2 and 1 in that order as
shown. If the bolt 1 is tightened first, the tensioner will move
with the bolt and cause the belt to become overtightened.
8.
Give the crankshaft one turn in operating direction (clockwise)
and realign crankshaft sprocket timing mark with the top dead
center position.
CAUTION:
Do
not turn the crankshaft in a reverse direction. The crank-
shaft should be turned smoothly clockwise.
9. Loosen the tensioner attaching bolts 1 and 2 in that order as
shown.

10. Retighten the tensioner attaching bolts 2 and 1 in that order as
shown to the specified torque.
Tightening torque
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-26 Nm (200-270 kg.cm, 14-20 Ib.ft)
11. Then recheck the belt tension. Verify that when the tensioner
and the tension side of the timing belt are pushed in horizon-
tally with a moderate force [approx. 49 N (11 lb)], the timing
belt cog end is approx. ½ of the tensioner mounting bolt head
radius (across flats) away from the bolt head center.
20-19
GENERAL
TENSION MEASURING PROCEDURE (When using
tension gauge)
1. Rotate crankshaft in direction of irregular rotation (counter-
clockwise) to position of 90 degrees before top dead center as
shown in illustration under condition that adjusting screw,
rocker arm is adjusted regularly (where valve clearance is
adjusted).
2. The measure bolt tension in the middle of tension side span.
Torque value of timing belt tension (In cool condition)
. . . . . . . . . . . . . . . . . . . . . . . . . 13 ± 3.5 kg (29 ± 7.7 lb)
CAUTION
(a) Put arm on bottom of belt teeth. And put spindle on the
middle of belt back surface.
(b) Keep hand off from indicating part.
20-20
ENGINE MOUNTING
ENGINE MOUNTING
COMPONENTS

TORQUE : Nm (kg-cm. Ib.ft)
20-21
ENGINE MOUNTING
REMOVAL
Attach a cable or chain to the engine hooks, and then lift enough
so that there is no pressure on the insulators.
Engine Mounting
1. Remove the engine mount insulator bolts.
2. Remove the engine mount bracket from the engine.
Transmission
1. For vehicles with a 5-speed manual transmission, remove the
select control valve.
2. Remove the transmission mount bolt.
3.
Detach the cap from the inside of the right fender shield, remove
the transmission mounting bolts.
4. Remove the transmission bracket.
Front Roll Stopper
1. Remove the front roll stopper upper and lower bolts.
2. Remove the front roll rod assembly.
20-22
ENGINE MOUNTING
Rear Roll Stopper
1. Remove the bolt from the rear roll stopper.
2. Remove the rear roll stopper from the No. 2 crossmember.
INSPECTION ITEMS
Transmission mounting
Engine mounting Front roll stopper
Rear roll stopper
BUSHING REPLACEMENT

Removal
1. Press out the bushings from the front roll stopper by using
special tools.
20-23
ENGINE MOUNTING
2. Press out the bushing from the rear roll stopper by using special
tools.
NOTE
Before removing the rear roll stopper bushing, mark the rear
roll stopper for reference in bushing installation.
Installation
1. Press fit the bushings into the front roll rod by using special
tools.
2.
Press fit the bushings into the rear roll stopper by using special
tools.
20-24
ENGINE MOUNTING
NOTE
When the bushings are installed, observe the following dimensions.
Front roll stopper
Rear roll stopper
NOTE
When installing the front roll stopper lower bolt, tighten the bolt
with its projection inserted into the slot.
20-25