HomeAbout UsCar EnginesMarine EnginesUsed EnginesArticlesRepairShippingResources
Site Map  |  FAQ  |  Contact Us
Marine Engines
Remanufactured Marine/Boat Engine
DIY Repair Manuals
Visit DIY!
Access Hyundai  wiring diagrams and repair procedures. Learn how to repair, install or remove a part, reset engine lights...
 
Hyundai  Engine Information
Home Page | Articles Home Page
Choose Your Vehicle Model Below
AccentAzeraElantraEntourage
ExcelGenesisGenesis CoupePony
Santa FEScoupeSonataStellar
TiburonTucsonVeracruzXG300
XG350
The following technical bulletins were published by AERA.
 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
 PISTON PROTRUSION SPECIFICATIONS
                                      Piston Protrusion Specifications On
                                          1986-93 Hyundai 1.5L Engines

AERA machinists should pay special attention when selecting and installing pistons on 1.5L Hyundai engines.  Beginning with the 1990 model year, a piston design modification increased the piston's installed height in the block.

To measure piston protrusion, first make certain that the piston is at top dead center.  Then, with the aid of a magnetic base dial indicator, measure the distance that the piston is above the block deck.  The proper protrusion for 1990-93 engines is .016 +/- .002.  Correct piston protrusion for earlier 1986-89 engines is classified as flush.

Use pistons with the Part #23410-21114 for 1986-89 engines and Part #23410-24220 for 1990-93 engines.  Aftermarket piston manufacturers should indicate a part number change in 1990 to reflect the change in OE piston design.

                                                                          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##
 VALVE TRAIN NOISE ON 1995-98 HYUNDAI 1.5L ENGINES
                                                      Valve Train Noise On
                                           1995-98 Hyundai 1.5L VIN C Engines

The AERA Technical Committee offers the following information regarding a valve train noise on 1995-98 1.5L VIN C engines. Vehicles that have received less than normal oil changes are likely candidates for this type of noise. 

It may be necessary to clean the valve lash adjusters on this engine as a small particle may have plugged the rocker arm oil feed passage to the lash adjuster. To properly clean out the lash adjusters, Hyundai offers the following information. 

1.	Remove the rocker arms from the rocker shaft, making sure to keep them in order. 

2.	Spray or dip the rocker arm in solvent.

3.	Blow compressed air, using a rubber tipped gun, through the lash adjuster as shown in Figure 1. Place your finger over the vent port on the topside of the rocker arm; this will force air through the oil passage back to the rocker shaft hole.  Using this compressed air, any particles lodged inside will be blown out the oil passage into the bore for the rocker shaft. 

4.	Spray the rocker arm oil passage with spray solvent using an applicator tube. If the passage is clear, solvent will squirt out into the lash adjuster bore. 

                                                                          The AERA Technical Committee
 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
 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
 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