1.5 Specifications

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2004 > G 1.5 SOHC > Language
SPECIFICATIONS
SPEC LIMIT
General
Type In-line, SOHC
No. of cylinder 4
Bore
1.3ℓ 71.5 mm (2.81 in.)
1.5ℓ 75.5 mm (2.97 in.)
Stroke 83.5 mm (3.29 in.)
Total displacement
1.3ℓ 1341 cc
1.5ℓ 1495 cc
Compression ratio
1.3ℓ 9.5
1.5ℓ 10.0
Firing order 1-3-4-2
Valve timing
Intake valve opens (BTDC) 12°
Intake valve closes (ABDC) 52°
Exhaust valve opens (BBDC) 52°
Exhaust valve closes (ATDC) 12°
Valve overlap 24°
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.08 mm (0.00315 in.)
Flatness of manifold mount'g surface Max. 0.15 mm (0.0059 in.) 0.3 mm (0.0118 in.)
Dimension for reworking oversize valve seat hole
Intake
0.03 O.S.
0.06 O.S. 28.8 ~ 28.821 mm (1.134 ~ 1.135 in.)
Exhaust 29.1 ~ 29.121 mm (1.146 ~ 1.1467 in.)
0.03 O.S.
0.06 O.S. 34.3 ~ 34.325 mm (1.350 ~ 1.351 in.)
Valve guide hole diameter (intake/exhaust) 34.6 ~ 34.625 mm (1.362 ~ 1.363 in.)
0.05 O.S.
0.25 O.S. 11.05 ~ 11.068 mm (0.435 ~ 0.436 in.)
0.50 O.S. 11.25 ~ 11.268 mm (0.443 ~ 0.4436in.)
11.50 ~ 11.518 mm (0.453 ~ 0.4535in.)
Camshaft
Cam height intake 42.8575 mm (1.687 in.) 42.3575 mm (1.667 in.)
Cam height exhaust 42.7354 mm (1.682 in.) 42.2624 mm (1.664 in.)
Journal diameter 30 mm (1.181 in.)
Bearing oil clearance 0.045 ~ 0.085 mm (0.0018 ~ 0.0033 in.)
End play 0.07 ~ 0.28 mm (0.0027 ~ 0.011 in.)
Crankshaft
Journal diameter 50 mm (1.97 in.)
Pin diameter 45 mm (1.77 in.)
Bend 0.03 mm (0.0018 in.)
Out of roundness of journal and pin Max. 0.005
Taper of journal and pin Max. 0.005
End play 0.05 ~ 0.175 mm (0.002 ~ 0.007 in.) 0.25 mm (0.0098 in.)
Undersize of Pin
0.25 44.725 ~ 44.740 mm (1.76 ~ 1.761 in.)
0.50 44.475 ~ 44.490 mm (1.75 ~ 1.751 in.)
0.75 44.225 ~ 44.240 mm (1.74 ~ 1.741 in.)
Undersize of Journal
0.25 49.727 ~ 49.742 mm (1.957 ~ 1.958in.)
0.50 49.477 ~ 49.492 mm (1.948 ~ 1.9485in.)
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0.75 49.227 ~ 49.242 mm (1.938 ~ 1.9386in.)

Main bearing oil clearance
No. 1,2,4,5 0.022 ~ 0.040 mm (0.0086 ~ 0.0016 in.) 0.1 mm (0.00394 in.)
No. 3. 0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)
Valve
Stem diameter
Intake 5.955 ~ 5.97 mm (0.234 ~ 0.235 in.)
Exhaust 5.935 ~ 5.95 mm (0.2336 ~ 0.234 in.)
Face angle 45° ~ 45.5°
Thickness of valve head (margin)
Intake 1.1 mm (0.043 in.) 0.8mm (0.031in.)
Exhaust 1.3 mm (0.051 in.) 1 (0.039 in.)
Valve stem to valve guide clearance
Intake 0.03 ~ 0.06 mm (0.0012 ~ 0.0024 in.) 0.1 mm (0.0039 in.)
Exhaust 0.05 ~ 0.08 mm (0.0020 ~ 0.0031 in.) 0.15 mm (0.006 in.)
Valve guide
Length
Intake 12.8 mm (0.504 in.)
Exhaust 12.8 mm (0.504 in.)
Service oversize 0.05, 0.25, 0.50
Valve seat
Width of seat contact
Intake 0.8 ~ 1.2 mm (0.031 ~ 0.047 in.)
Exhaust 1.3 ~ 1.7mm (0.051 ~ 0.067 in.)
Seat angle 45°
Service oversize 0.3, 0.6
Valve spring
Free length (Installed height) 44 mm (1.732 in.)
Load 21.6kg/35mm, 45.1kg/27.2mm
Out of squareness Max 1.5
Cylinder block
Cylinder bore
1.3ℓ 71.5 ~ 71.53 mm (2.815 ~ 2.816 in.)
1.5ℓ 75.5 ~ 75.53 mm (2.9724 ~ 2.9736 in.)
Out of roundness of cylinder bore Max. 0.01
Taper of cylinder bore -
Flatness of gasket surface Max. 0.05 0.1 mm (0.0039 in.)
Piston
Dameter
1.3ℓ 71.47 ~ 71.50 mm (2.814 ~ 2.815 in.)
1.5ℓ 75.47 ~ 75.50 mm (2.9713 ~ 2.9724 in.)
Piston to cylinder clearance 0.02 ~ 0.04 mm (0.0078 ~ 0.00157 in.)
Piston ring
No. of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No. 1 Inside bevel type, steel
No. 2 Taper type
Oil ring type 3 - piece type
Side clearance
No. 1 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.1 mm (0.00394 in.)
No. 2 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.) 0.1 mm (0.00394 in.)
Oil ring 0.06 ~ 0.15 mm (0.0023 ~ 0.006 in.)
End gap
No. 1 0.15 ~ 0.30 mm (0.0059 ~ 0.012 in.) 1 mm (0.0394 in.)
No. 2 0.30 ~ 0.45 mm (0.012 ~ 0.0177 in.) 1 mm (0.0394 in.)
Oil ring side rail 0.2 ~ 0.7 mm (0.008 ~ 0.028 in.) 1 mm (0.0394 in.)
Sevice oversize 0.25, 0.50, 0.75, 1.0
Connecting rod
Bend Max. 0.05 per 100 mm
Twist Max. 0.1 per 100mm
Connecting rod big end to crankshaft side 0.10 ~ 0.25 mm (0.004 ~ 0.01 in.) 0.4 mm (0.016 in.)
clearance
Piston pin press in load 1250 ± 500 kg
Bearing oil clearance 0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in.) 0.1 mm (0.0039 in.)
Flywheel
Runout 0.1mm (0.0014 in.) 0.13 mm (0.005 in.)
Oil pressure at curb idle speed (oil temp. 1.5kg / cm²
90~110°C)
Oil pump
Clearance between outer circum - ference and 0.12 ~ 0.18 mm (0.0047 ~ 0.0071 in.)
front
Clearance between rotor axial side and front 0.04 ~ 0.085 mm (0.0016 ~ 0.0033 in.)
case
Tip clearance between outer and inner rotor 0.025 ~ 0.069 mm (0.0010 ~ 0.0027 in.)
Relief spring
Free length 46.6 mm (1.8346 in.)
Load 6.1kg at 40.1 mm (13.4216 at 1.578 in.)
Cooling method Water-cooled, Pressurized, Forced
circulation with electrical fan
Cooling sys. Quantity
1.3ℓ 6.2 lit (6.55 U.S qts 5.46 lmp qts)
1.5ℓ 6.5 lit (6.87 U.S. qut, 5.72 lmp qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temp. 82°C
Opening temp. range 80.5 ~ 83.5°C
Wide opening temp. 95°C
Radiator cap
Main valve opening pressure 86.1 ~ 124.5 kpa
Main valve colseing pressure 83.4 kpa
Vacuum valve opening preesur -86.6 kpa
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension sys. Rubber hanger type
TIGHTENING TORQUE (1.3 /1.5 L)

Item Nm kg.cm lb.ft
Cylinder Block
Left engine support bracket bolt 30 ~ 42 300 ~ 420 22 ~ 31
Oil pressure switch 13 ~ 15 130 ~ 150 9.6 ~ 11
Cylinder head
Cylinder head bolt (23 ~ 27) + (60° ~ 62°) + (60° (230 ~ 270) + (60° ~ 62°) + (17 ~ 20) +
~ 62°) (60° ~ 62°) (60° ~ 62°)
Intake/manifold bolts or nuts 15 ~ 20 150 ~ 200 + (60° ~
Exhaust manifold nut 15 ~ 20 150 ~ 200 62°)
Recker cover bolt 8 ~ 10 80 ~ 100 11 ~ 15
Recker arm shaft bolt 20 ~ 24 20 ~ 240 11 ~ 15
Camshaft bolt 20 ~ 27 200 ~ 270 6~7
Rear plate bolt 8 ~ 10 80 ~ 100 15 ~ 18
15 ~ 20
6~7
Main Moving parts
Connecting rod cap nut 32 ~ 35 320 ~ 350 24 ~ 26
Crankshaft bearing cap bolt 55 ~ 60 550 ~ 600 41 ~ 44
Flywheel M/T bolt 130 ~ 140 1300 ~ 1400 96 ~ 103
Drive plate A/T bolt 130 ~ 140 1300 ~ 1400 96 ~ 103
Timing Belt
Crankshaft sprocket bolt 140 ~ 150 1400 ~ 1500 103 ~ 111
Camshaft sprocket bolt 80 ~ 100 800 ~ 1000 59 ~ 74
Timing belt tensioner bolt 20 ~ 27 200 ~ 270 15 ~ 20
Timing belt cover bolt 10 ~ 12 100 ~ 120 7~9
Front case bolt 12 ~ 15 120 ~ 150 9 ~ 11
Engine Mounting
Engine mounting insulator bolt 90 ~ 110 900 ~ 1100 66.4 ~
Engine mounting bracket to engine nuts and 50 ~ 65 500 ~ 650 81.1
bolts 36.9 ~
Transaxle mount insulator bolt 90 ~ 110 900 ~ 1100 48.0
Transaxle insulator bracket to side member bolts 30 ~ 40 300 ~ 400
Front roll stoper insulator bolt 66.4 ~
Front roll stoper bracket to sub-frame bolt 45 ~ 60 450 ~ 600 81.1
Rear roll stoper insulator bolt 30 ~ 40 300 ~ 400 22.1 ~
Rear roll stoper bracket to sub-frame bolt 45 ~ 60 4520 ~ 600 29.5
30 ~ 40 300 ~ 400
33.2 ~
44.3
22.1 ~
29.5
33.2 ~
44.3
22.1 ~
29.5
Oil filter 12 ~ 16 120 ~ 160 9 ~ 12
Oil pan bolts 6~ 8 60 ~ 80 4~6
Oil pan drain plug 35 ~ 45 350 ~ 450 26 ~ 33
Oil screen bolts 15 ~ 22 150 ~ 220 11 ~ 16
Timing belt upper cover bolts 10 ~ 12 100 ~ 120 7~9
Timing belt lower cover bolts 10 ~ 12 100 ~ 120 7~9
Surge tank to inlet manifold nuts and bolts 15 ~ 20 150 ~ 200 11 ~ 15
Alternator support and nut 20 ~ 25 200 ~ 250 15 ~ 18
Alternator lock bolt 15 ~ 22 150 ~ 220 11 ~ 16
Alternator brace mounting bolt 20 ~ 28 200 ~ 280 15 ~ 21
Cooling system
Coolant pump pulley 8 ~ 10 80 ~ 100 6~7
Coolant pump bolt 12 ~ 15 120 ~ 150 9 ~ 11
Coolant temperature gauge unit 10 ~ 12 100 ~ 120 7~9
Coolant temperature sensor 15 ~ 20 150 ~ 200 11 ~ 15
Coolant outlet fitting bolt 17 ~ 20 170 ~ 200 13 ~ 15
Thermostat housing bolt 15 ~ 20 150 ~ 200 11 ~ 15
Intake and Exhaust system
Air cleaner body mounting bolts 8 ~ 10 80 ~ 100 6~ 7
Resonator mounting bolts 4~6 40 ~ 60 2.9 ~ 4.3
Throttle body to surge tank bolts 15 ~ 20 150 ~ 200 11 ~ 15
Oxygen sensor to exhaust manifold 50 ~ 60 500 ~ 600 37 ~ 44
Front exhaust pipe to exhaust manifold nuts 30 ~ 40 300 ~ 400 22 ~ 30
Front exhaust pipe bracket bolts 30 ~ 40 300 ~ 400 22 ~ 30
Front exhaust pipe to cataiytic converter bolts 40 ~ 60 400 ~ 600 30 ~ 44
SELECTION OF ENGINE OIL
For best performance and maximum protection of all types of operation, select only those lubricants below :
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.
MAINTENANCE
CHECKING ENGINE OIL
1. Position the vehicle on a level surface.
2. Warm up the engine.
If a vehicle has been out of service for a prolonged period of time, warm up the engine for approximately 20 minutes.
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 ragne 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.
When refilling, use the same type of engine oil.
5. Check that the oil is not dirty or contaminated with coolant or gasoline and that it has proper viscosity.
CHANGING ENGINE OIL
Be careful not to brun yourself, as the engine oil is hot.
1. Run the enigne 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.
4. Install and tighten the drain plug to the specified torque.
Tightening torque
Drain plug : 35 ~ 45 Nm (350 ~ 450 kg.cm, 24 ~ 33 lb.ft)
Whenever tightening the oil drain plug, use a new drain plug gasket.
5. Fill the crankcase with fresh engine oil through the oil filler cap opening.
Drain and Refill Without oil filter

3.0 liter (3.17 U.S. qts., 2.64 lmp. qts.)
Drain and Refill With oil filter
3.3 liter (3.48 U.S. qts., 2.90 lmp. qts.)
6. Install the oil filler cap.

7. 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 dquipped 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 be fore installing the new filter.
PROCEDURE FOR REPLACING THE OIL FILTER

Be careful not to burn ylurself, as the engine and engine oil are not.
1. Use a filter wrench to remove the oil filter.

2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
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.
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, 20 psi) pressure. Hold it for two
minutes in that condition, while checking for leakage from the radiator, hoses or connections.
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.
4. If there is leakage, repair or replace with the apropriate part.
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.
Main valve opening pressure :

78 ~ 108 kPa (0.8 ~ 1.1 kg/cm², 11.3 ~ 15.6 psi)
Limit : 65 kPa (0.66 kg/cm², 9.2 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.
Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an
incorrect reading.
CHANGING ENGINE COOLANT
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.
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.
4. Tighten the radiator drain plug securely.

5. Remove, drain and reinstall the reservior.
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.
7. 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.
SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.
2. Mesure the coolant temperature and calculate the concentration from the relation between the specific gravity and
temperature, using the following table for reference.
RELATION BERWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C (°F) and specific gravity Coolant

Freezing Safe operating
concentration
temperature °C temperature °C
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) (Specific
(°F) (°F)
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 -20 (-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%
• 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 antifreeze 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 brand's product.
RECOMMENDED COOLANT
Antifreeze Mixture ratio of anti freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas]
40% [Tropical areas]
CHECKING COMPRESSION PRESSURE

1. Befor 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 resetting the ECM will erase any stored DTCs.
3. Stsrt the engine and wait until engine coolant temperature reaches 80~95°C (176~205°F).
4. Disconnect the fuel pump connector.
5. Turn off engine and disconnect the spark plug cables.
6. Remove the spark plug.

7. 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.
10. Depress the accelerator pedal to open the throttle fully.

11. Crank the engine and read the gauge.
Standard value : 1500 kpa (15.5 kg/cm², 220 psi)

Limit : 1200 kpa (12.5 kg/cm², 178 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. 150 kpa (1.5 kg/cm², 21 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.
A. 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.
B. If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head
gasket are all possible causes.
Tightening torque
Spark plug : 20~30 Nm (200~300 kg.cm, 14~22 lb.ft)
ADJUSTING TIMING BELT TENSION

1. Turn the steering wheel fully counter clock wise.
2. Lift the vehicle by using of jack.
3. Remove the engine support bracket.
4. Loosen the coolant pump pulley mounting bolt and loosen the generator belt tension adjustment bolt.
5. Remove the coolant pump pulley, generator belt, power steering pulley and power steering belt.
6. Remove the timing cover upper side mounting bolt.
7. Remove the crankshaft pulley.
8. Turn crankshaft to place clockwise in No.1 cylinder at top head center on compression stroke.
Turn the crankshaft clock wise. If counter clock wise, tension is not available.
9. Loosen the tensioner bolt 1 ~ 2 turn and tension the belt by tensioner spring.
10. Turn crankshaft clockwise as much as two camshaft sprocket teeth.

11. Tighten the tensioner bolt of slot side of first and then tighten the bolt of pivot side.
12. Rotate the crankshaft pulley two turns clockwise so that the timing belt positions on the pulleys.
13. Check the tension of timing belt.
When the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N
(11 lb)], the timing belt log end is approx. half of the tensioner mounting bolt head radius (cross flats) away from the bolt
head center.
14. Install the timing belt cover.
Tightening torque :
10 ~ 12 Nm (100 ~ 120 kg.cm, 7.2 ~ 8.7 lb.ft)
15. Install the crankshaft pulley.

16. Install the coolant pump pulley.
17. Install V-belt and adjust the belt tension.
ADJUSTING DRIVE BELT TENSION

1. Check that the belts are not damaged and are properly fit for the pulley grooves.
2. Apply 100 N (22 lbs.) force to the back and midway portion of the belt between the pulleys as shown in the illustration,
measure the amount of deflection with a tension gauge.
1. When installing the V-ribbed belt, check that the V-ribs are properly aligned.
2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact surface, and
check the pulley for scoring. Also check the amount that the belt is deflected.
STANDARD VALUE :
Adjustment
Items
New Used
For alternator Deflection mm (in.) 7.5 ~ 9.0 (0.29 ~ 0.35) 10 (0.39)
1. The belt tension must be measured half - way between the specified pulleys.
2. When a new belt is installed, adjust the tension to the central value of the standard range indicated under "New"
in the above table. Let the engine idle for 5 minutes or more, and check the standard value indicated under
"Inspection".
3. When adjusting a belt which has been used, or newly installed, after 5 minutes or more of operation, refer to the
standard value indicated under "Used" in the above table.
4. Refer to the standard value indicated under "Inspection" for periodic inspections.
TYPE A TENSION GAUGE
TYPE B TENSION GAUGE

1. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET position.
2. If the tension gauge is removed from the belt, the needle will still indicate the tension. Read the tension value after removing
the gauge.
ADJUSTING THE ALTERNATOR BELT
If the belt is too loose, it will cause noise or sudden wear.

If the belt is too tight, the engine coolant pump bearing or the alternator can get damaged.
1. Loosen the alternator nut "A" and the tension adjuster lock the bolt "B"
2. Using the tension adjuster bolt, adjust the belt tension to the specification.
3. Tighten the adjuster lock bolt "B".
4. Tighten the alternator nut "A".
5. Check the tension or the deflection of belt, readjust if necessary.
Tightening torque
Alternator support nut A :
20 ~ 25 Nm (200 ~ 250 kg.cm, 15 ~ 18 lb.ft)
Alternator lock bolt B :
15 ~ 22 Nm (150 ~ 220 kg.cm, 11 ~ 16 lb.ft)
Alternator brace mounting bolt :

20 ~ 28 Nm (200 ~ 280 kg.cm, 15 ~ 21 lb.ft)
TIGHTENING TORQUE
Item Nm kg.cm lb.ft
Cylinder Block
Front engine support bracket bolt and nut 30-42 300-420 22-31
Left engine support bracket bolt 30-42 300-420 22-31
Oil pressure switch 13-15 130-150 9.6-11
Cylinder head
Cylinder head bolt (23~27)+ (230~270) (17~20)
(60°-62°)+ + +
(60°~62°) (60°~62°) (60°~62°)
+ +
(60°~62°) (60°~62°)
Intake/manifold bolts or nuts 15-20 150-200 11-15
Exhaust manifold nut 15-20 150-200 11-15
Rocker cover bolt 8-10 80-100 6-7
Rocker arm shaft bolt 20-24 20-240 15-18
Camshaft bolt 20-27 200-270 15-20
Rear plate bolt 8-10 80-100 6-7
Main Moving parts
Connecting rod cap nut 32-35 320-350 24-26
Crankshaft bearing cap bolt 55-60 550-600 41-44
Flywheel M/T bolt 130-140 1300- 96-103
1400
Drive plate A/T bolt 130-140 1300- 96-103
1400
Timing Belt
Crankshaft sprocket bolt 140-150 1400- 103-111
1500
Camshaft sprocket bolt 80-100 800-1000 59-74
Timing belt tensioner bolt 20-27 200-270 15-20
Timing belt cover bolt 10-12 100-120 7-9
Front case bolt 12-15 120-150 9-11
Engine Mounting
Right mounting insulator (large) nut 90-110 900-1100 66-81
Right mounting insulator (small) nut 50-65 500-650 37-48
Right mounting bracket to engine nuts and bolts 50-65 500-650 37-48
Transaxle mount insulator nut 90-110 900-1100 66-81

Transaxle insulator bracket to side member bolts 30-40 300-400 22-30
Rear roll stopper insulator nut 45-60 450-600 33-44
Rear roll stopper bracket to sub-frame bolts 30-40 300-400 22-30
Front roll stopper insulator nut 45-60 450-600 33-44
Front roll stopper bracket to sub-frame bolts 30-40 300-400 22-30
Oil filter 12-16 120-160 9-12
Oil pan bolts 6-8 60-80 4-6
Oil pan drain plug 35-45 350-450 26-33
Oil screen bolts 15-22 150-220 11-16
Timing belt upper cover bolts 10-12 100-120 7-9
Timing belt lower cover bolts 10-12 100-120 7-9
Surge tank to inlet manifold nuts and bolts 15-20 150-200 11-15
Cooling system
Generator support and nut 20-25 200-250 15-18
Generator lock bolt 15-22 150-220 11-16
Generator brace mounting bolt 20-28 200-280 15-21
Coolant pump pulley 8-10 80-100 6-7
Coolant pump bolt 12-15 120-150 9-11
Coolant temperature gauge unit 10-12 100-120 7-9
Coolant temperature sensor 15-20 150-200 11-15
Coolant outlet fitting bolt 17-20 170-200 13-15
Thermostat housing bolt 15-20 150-200 11-15
Intake and Exhaust system
Air cleaner body mounting bolts 8-10 80-100 6-7
Resonator mounting bolts 4-6 40-60 2.9-4.3
Intake manifold to cylinder head nuts and bolts 15-20 150-200 11-15
Throttle body to surge tank bolts 15-20 150-200 11-15
Exhaust manifold to cylinder head nuts 15-20 150-200 11-15
Exhaust manifold cover to exhaust manifold 15-20 150-200 11-15
bolts
Oxygen sensor to exhaust manifold 50-60 500-600 37-44
Front exhaust pipe to exhaust manifold nuts 30-40 300-400 22-30
Front exhaust pipe bracket bolts 30-40 300-400 22-30
Front exhaust pipe to catalytic converter 40-60 400-600 30-44
bolts
Catalytic converter to main muffler ass'y 30-40 300-400 22-30
nuts
SERVICE STANDARD
Standard value
Antifreeze Mixture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50 %
SELECTION OF LUBRICANTS
Engine Oil
1. Conform to the requirements of API classification.

2. Have a proper SAE grade number for the expected temperature range.
SPECIFICATIONS
Description Specification Limit
General Type In-line 12 valve OHC

Number of cylinders 4
1.5L Eng 1.3L Eng.
Bore 75.5 mm (2.97 in.) 71.5mm(2.81in.)
Stroke 83.5 mm (3.29 in.) 83.5mm(3.29in.)
Total displacement 1495 CC 1341 CC
Compression ratio 10.0 9.5
Firing order 1-3-4-2 1-3-4-2
Idle R.P.M 800± 100 800±100
Ignition timing at idling BTDC 9°±5°/800 rpm BTDC 9°
speed ±5°/800rpm
Valve timing Intake valve Opens (BTDC) 12°
Closes (ABDC) 52°
Exhaust valve Opens (BBDC) 52°
Closes (ATDC) 12°
Cylinder head Flatness of gasket Max. 0.03 mm (0.0012 in.) 0.08 mm

surface (0.0031 in.)
Flatness of manifold Max. 0.15 mm (0.0059 in.) 0.3 mm (0.0118

mounting surface in.)
Oversize rework Intake 0.3 mm (0.012 in.) O.S. 28.8-28.821 mm
dimensions of valve (1.134-1.135 in.)
seat hole
0.6mm (0.024 in.) O.S 29.1-29.121 mm
1.146-1.1467in.)
Exhaust 0.3mm (0.012 in.) O.S. 34.3-34.325 mm
(1.350-1.351in.)
0.6mm (0.024 in.) O.S. 34.6-34.625 mm
(1.362-1.363 in.)
Oversize rework 0.05mm (0.002 in.) O.S. 11.05-11.068 mm (0.435-0.4357
dimensions of valve in.)
guide hole (both intake
0.25mm (0.010 in.) O.S. 11.25-11.268 mm (0.443-0.4436
and exhaust)
in.)
0.50mm (0.020 in.) O.S. 11.50-11.518 mm (0.453-0.4535
in.)
Camshaft Cam height Intake 42.8575 mm (1.6873 in.) 42.3575 mm

(1.6676 in.)
Exhaust 42.7354 mm (1.6825 in.) 42.2624 mm
(1.6628 in.)
Journal O.D. 30 mm (1.181 in.)
Bearing oil clearance 0.045-0.085 mm (0.0020-0.0035
in.)
End play 0.07-0.28 mm (0.003-0.011 in.)
Valve Stem O.D. Intake 5.97-5.955 mm (0.235-0.234 in.)
Exhaust 5.965-5.95 mm (0.235-0.234 in.)
Face angle 45-45.3 °
Thickness of valve Intake 1.1mm (0.043 in.) 0.8 mm
head (margin) (0.031in.)
Exhaust 1.4mm (0.055 in.) 1.0 mm (0.039

in.)
Valve stem to Intake 0.03-0.06 mm (0.0012-0.0024 in.) 0.10mm (0.0039
valve guide in.)
clearance
Exhaust 0.035-0.065 mm (0.0014-0.0026 0.5 mm (0.019
in.) in.)
Valve guide Installed dimension O.D Intake 10.05 mm (0.3957 in.)
Exhaust 11 mm ( 0.4331 in.)
Service size 0.05, 0.25, 0.50 mm, (0.002,
0.010, 0.020 in.) oversize
Valve seat insert Width of seat contact Intake 0.8- 1.2 mm (0.031- 0.047 in.)
Exhaust 1.5- 1.9 mm (0.059- 0.075 in.)
Seat angle 45°
Oversize 0.3mm(0.012in.),0.6mm(0.024in.)
Valve spring Free length 42.03mm(1.655 in,)

Load 24.7±1.2 kg/ 34.5 mm at height
54.6± 2.7kg/ 25.9 mm at height
Installed height 34.5 mm (1.358 in.)
Squareness 1.5° or less
Cylinder block Cylinder bore 75.50- 75.53 mm (2.9724- 2.9736
in.)
Out-of-roundness and Less than 0.01 mm (0.0004 in.)
taper of cylinder bore
Clearance with piston 0.02- 0.04 mm (0.0008- 0.0016
in.)
Piston O.D. 75.47- 75.50 mm (2.9713- 2.9724
in.)
Service size 0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.)
oversize
Piston ring Side clearance No. 1, No. 2 0.04-0.085 mm (0.0016- 0.1 mm (0.004
0.0033in.) in.)
End gap (1.5 L Eng.) No. 1 0.20-0.35 mm (0.0078-0.0196 in.) 1 mm (0.0394
in.)
No. 2 0.37-0.52 mm (0.0078-0.0196 in.) 1 mm (0.0394
in.)
Oil ring side rail 0.25-1.00 mm (0.0078-0.0394 in.) 1 mm (0.0394
in.)
Service size 0.25, 0.50, 0. 75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.)
Connecting rod Bend 0.05 mm (0.0019 in.) or less
Twist 0. 1 mm (0.0394in.) or less
Connecting rod big end 0.10-0.25mm(0.0039-0.0098 in.) 0.4mm (0.0157
to crankshaft side in.)
clearance
Connecting rod Oil clearance 0.018-0.036 mm (0.0007-0.0014
bearing in.)
Undersize 0.25 mm, 0.50 mm, 0.75 mm
(0.01 in., 0.02in., 0.03 in.)
Crankshaft Pin O.D. 45 mm (1.7717 in.)
Journal O.D. 50 mm (1.9685 in.)
Bend 0.03 mm or less
Out-of-roundness, taper 0.005 mm (0.0004 in.) or less
of journal and pin
End play 0.05-0.175 mm (0.0020-0.0069
in.)
Undersize rework 0.25 mm (0.010 in.) 44.704- 44.722 mm (1.7600-
dimension of pin 1.7607 in.)
0.50 mm (0.020 in.) 44.454- 44.472mm (1.7502-
1.7509 in.)
0.75 mm (0.030 in.) 44.204- 44.222 mm (1.7403-
1.7410 in.)
Undersizd rewodk 0.25 mm (0.010 in.) 49.700-49.718 mm (1.9567-

dimension of journal 1.9574 in.)
0.50 mm (0.020 in.) 49.450- 49.468 mm (1.9469-
1.9476 in.)
0.75 mm (0.030 in.) 49.200- 49.218 mm (1.9370-
1.9377 in.)
Flywheel Runout 0.1 mm (0.0039 in.) 0.13 mm
(0.0051 in.)
Oil pump Clearance between 0.12- 0.18 mm 90.0047- 0.0070
outer circumference in.)
and front case.
Clearance between 0.04- 0.065 mm (0.0016- 0.0026
roter axial side and in.)
front case
Tip clearance between 0.0025- 0.069 mm (0.0010-
outer and inner roter 0.0027 in.)
Engine oil pressure Engine at idle speed 147 KPa (1.5 kg/cm² 21.33 psi)
Relief spring : Free height 46.6 mm (1.8346 in.)
: Load 6.1 kg at 40.1 mm (13.42 lb at
1.578 in.)
Water-cooled,
Cooling method Pressurized,Forced
circulation with
electrical fan
Coolant Quantity 6 lit (7 U.S qts.,
6.9 lmp. qts.)
Radiator Type Pressurized
corrugated fin type
Performance 38000 Kcal/h
Radiator cap Main valve opening pressure 81.4-108 kpa (11.8-
15.6 psi.,0.83-
1.1kg/cm² )
Vacuum valve opening pressure -6.86 kpa (-1.00
psi, -0.07 kg/cm² or
less
Coolant pump Centrifugal type
impeller
Thermostat Type Wax pellet type
with jiggle valve
Valve opening temperature 88°C(190°F)
Full-opening temperature 100°C (212°F)
Valve lift, when fully open 8 mm (0.32 in) or
more at 100°C
(212°F)
Identification mark 88 (Stamped on
flange)
Drive belt Type V-ribbed belt
Engine coolant temperature gauge unit Type Thermistor type
Resistance 42.4-54.4 Ω at
85°C 185°F)
22.1-26.2 Ω at
110°C (230°F)
Engine coolant temperature sensor Type Thermistor type
Resistance 2.31-2.59 kΩ at
20°C(68°F)
146.9Ω-147.3Ωat
110° C(230°F)
Switching temperature
Automatic transaxle Performance 1,200 Kcal/h
Type Dry type
Air cleaner
Element Unwoven cloth type
Muffler Expansion
Exhaust pipe resonance type
Suspension system Rubber hangers

1.5 Specifications

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21/09/2012service.hyundai-motor.com/Viewer/content.asp?

2004 > G 1.5 SOHC > Language

0.75 49.227 ~ 49.242 mm (1.938 ~ 1.9386in.)

TIGHTENING TORQUE (1.3 /1.5 L)

SELECTION OF ENGINE OIL

When refilling, use the same type of engine oil.

CHANGING ENGINE OIL

Be careful not to brun yourself, as the engine oil is hot.

1. Run the enigne until it reaches normal operating temperature.

4. Install and tighten the drain plug to the specified torque.

Drain and Refill Without oil filter

6. Install the oil filler cap.

PROCEDURE FOR REPLACING THE OIL FILTER

1. Use a filter wrench to remove the oil filter.

3. Tighten the oil filter to the specified torque.

4. Run the engine to check for engine oil leaks.

CHECKING COOLANT LEAK

4. If there is leakage, repair or replace with the apropriate part.

RADIATOR CAP PRESSURE TEST

Main valve opening pressure :

3. Check that the pressure level is maintained at or above the limit.

CHANGING ENGINE COOLANT

4. Tighten the radiator drain plug securely.

SPECIFIC GRAVITY TEST

RELATION BERWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY

Coolant temperature °C (°F) and specific gravity Coolant

CHECKING COMPRESSION PRESSURE

6. Remove the spark plug.

8. Crank the engine to remove any foreign material in the cylinders.

10. Depress the accelerator pedal to open the throttle fully.

Standard value : 1500 kpa (15.5 kg/cm², 220 psi)

Limit : Max. 150 kpa (1.5 kg/cm², 21 psi)

ADJUSTING TIMING BELT TENSION

3. Remove the engine support bracket.

7. Remove the crankshaft pulley.

10. Turn crankshaft clockwise as much as two camshaft sprocket teeth.

14. Install the timing belt cover.

15. Install the crankshaft pulley.

ADJUSTING DRIVE BELT TENSION

TYPE A TENSION GAUGE

TYPE B TENSION GAUGE

ADJUSTING THE ALTERNATOR BELT

If the belt is too loose, it will cause noise or sudden wear.

Alternator brace mounting bolt :

Transaxle mount insulator nut 90-110 900-1100 66-81

1. Conform to the requirements of API classification.

Description Specification Limit

General Type In-line 12 valve OHC

Cylinder head Flatness of gasket Max. 0.03 mm (0.0012 in.) 0.08 mm

Flatness of manifold Max. 0.15 mm (0.0059 in.) 0.3 mm (0.0118

Camshaft Cam height Intake 42.8575 mm (1.6873 in.) 42.3575 mm

Exhaust 1.4mm (0.055 in.) 1.0 mm (0.039

Valve spring Free length 42.03mm(1.655 in,)

Undersizd rewodk 0.25 mm (0.010 in.) 49.700-49.718 mm (1.9567-

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