Hyundai Accent GL 2002 Manual Download Page 38

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Fig. 35: Measuring Cylinder Bore Diameter
Courtesy of HYUNDAI MOTOR CO.

4. If a cylinder ridge exists, cut away with a ridge reamer.

5. Oversize pistons are available in four sizes.

Piston service size and mark mm (in.)

0.25 (0.010) O.S.: 0.25

0.50 (0.020) O.S.: 0.50

0.75 (0.030) O.S.: 0.75

1.00 (0.039) O.S.: 1.00

2002 Hyundai Accent GL

2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent

viernes, 19 de febrero de 2021 07:12:57 a. m.

Page 38

Summary of Contents for Accent GL 2002

Page 1: ...2 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 1...

Page 2: ...on Table 2 Of 4 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 2 2011 Mitchell Repair Informa...

Page 3: ...on Table 3 Of 4 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 3 2011 Mitchell Repair Informa...

Page 4: ...pplication Ft Lbs N m Alternator Brace Bolt 15 20 20 27 Alternator Support Fasteners 15 18 20 25 Camshaft Sprocket Bolt 59 74 80 100 Connecting Rod Cap Nut 24 26 32 35 Coolant Inlet Fitting Bolt 13 14...

Page 5: ...nifold Nut 18 22 25 30 Exhaust Pipe Front Bracket Bolt 22 30 30 40 Exhaust Pipe To Catalytic Converter 30 40 40 60 Exhaust Pipe To Exhaust Manifold Nut 22 30 30 40 Front Case Bolt 15 20 20 27 Intake M...

Page 6: ...ng Bolt 27 35 4 6 Timing Belt Cover Bolt 71 89 8 10 1 Tighten cylinder head bolts in sequence See Fig 5 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febre...

Page 7: ...Head Tightening Sequence Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 7 2011 Mitchell Repa...

Page 8: ...ice Standard Courtesy of HYUNDAI MOTOR CO SPECIAL TOOLS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 8 2011 Mitchell Rep...

Page 9: ...ecial Tools 1 Of 2 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 9 2011 Mitchell Repair Info...

Page 10: ...ols 2 Of 2 Courtesy of HYUNDAI MOTOR CO TROUBLESHOOTING 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 10 2011 Mitchell Re...

Page 11: ...ing Table 1 Of 2 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m Page 11 2011 Mitchell Repair Infor...

Page 12: ...ck If the oil level is found to have fallen to the lower limit the L mark refill to the F mark Fig 11 Locating Dipstick Level Range Indication Courtesy of HYUNDAI MOTOR CO NOTE If a vehicle has been o...

Page 13: ...lug on the oil pan Drain the engine oil Fig 12 Identifying Drain Plug Courtesy of HYUNDAI MOTOR CO 4 Install and tighten the drain plug to the specified torque Tightening torque Drain plug 35 45Nm 350...

Page 14: ...e 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...

Page 15: ...fore installing the new oil filter on the engine apply clean engine oil to the surface of the rubber gasket CAUTION Be careful not to burn yourself as the engine and engine oil are hot 2002 Hyundai Ac...

Page 16: ...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 SG OR ABOVE For EC Recommended SAE vis...

Page 17: ...only those lubricants which NOTE 1 Satisfy the requirements of the API classification 2 Have proper SAE grade number for expected ambient temperature range NOTE Lubricant that does not have both an SA...

Page 18: ...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 pl...

Page 19: ...heck 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 NOTE Be sure that the cap is clean before testing since...

Page 20: ...hydrometer 2 Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature using Fig 19 for reference 2002 Hyundai Accent GL 2002 ENGI...

Page 21: ...of HYUNDAI MOTOR CO RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a m...

Page 22: ...til engine coolant temperature reaches 80 95 C 176 205 F 3 Turn off engine and disconnect the spark plug cables 4 Remove the spark plugs CAUTION If the concentration of the coolant is below 30 its ant...

Page 23: ...rs 10 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 6 to 9 1 If the addition of oil makes the...

Page 24: ...sing of jack 2 Rotate the steering wheel counter clockwise thoroughly 3 Remove the engine support bracket NOTE Do watch not to over load 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOH...

Page 25: ...UNDAI MOTOR CO 4 Remove the water pump pulley 5 Remove the timing belt upper cover 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 57 a...

Page 26: ...to TDC of the compression stroke by rotating the crankshaft clockwise NOTE Crankshaft is to be rotated clockwise otherwise the tension is inadequately adjusted 2002 Hyundai Accent GL 2002 ENGINE Engin...

Page 27: ...e the crankshaft clockwise as many as 2 teeth of sprocket NOTE Set the exhaust valve rocker arm to upper position of cam in order to be the specified tension 2002 Hyundai Accent GL 2002 ENGINE Engine...

Page 28: ...t bracket 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...

Page 29: ...he 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 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical...

Page 30: ...or 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 v...

Page 31: ...ON GAUGE Do not let the dial section of the tension gauge contact other objects during measurement 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de...

Page 32: ...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 2002 Hyundai A...

Page 33: ...rnator nut A 5 Check the tension or the deflection of belt readjust if necessary Tightening torque Alternator support bolt and nut 20 25 Nm 200 250 kg cm 14 18 lb ft CAUTION If the belt is too loose i...

Page 34: ...200 270 kg cm 15 20 lb ft Fig 31 Adjusting Alternator Belt Courtesy of HYUNDAI MOTOR CO ENGINE BLOCK ENGINE BLOCK COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accen...

Page 35: ...the cylinder head timing belt front case flywheel pistons and crankshaft 2 Remove the oil pressure switch 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de fe...

Page 36: ...2 Using a straight edge and feeler gauge check the top surface of the block for warpage Make sure that the surface is free from gasket chips or other foreign material Standard 0 03 mm 0 0012 in or le...

Page 37: ...ut of round or taper or if the cylinder walls are badly scuffed or scored the cylinder block should be rebored and honed Oversize pistons and rings must be fitted Cylinder I D 76 5 76 53 mm 3 0118 3 0...

Page 38: ...ersize pistons are available in four sizes Piston service size and mark mm in 0 25 0 010 O S 0 25 0 50 0 020 O S 0 50 0 75 0 030 O S 0 75 1 00 0 039 O S 1 00 2002 Hyundai Accent GL 2002 ENGINE Engine...

Page 39: ...e The standard measurement of the piston s outside diameter is taken 47 mm 1 85 in from the top land of the piston Piston to cylinder clearance 0 025 0 045 mm 0 0010 0 0018 in ENGINE MOUNTS COMPONENTS...

Page 40: ...gine hoist to the engine hooks and raise the engine just enough so that there is no pressure on the insulators 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 d...

Page 41: ...MOUNTING 1 Remove the engine mounting insulator bolts 2 Remove the engine mounting bracket from the engine 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de f...

Page 42: ...1 For vehicles with a 5 speed manual transmission remove the select control valve 2 Remove the transmission mounting bolt 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent v...

Page 43: ...cap from inside the right fender shield Remove the transmission mounting bolts 4 Remove the transmission bracket 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 1...

Page 44: ...YUNDAI MOTOR CO FRONT ROLL STOPPER 1 Remove the front roll stopper bracket from the subframe 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021...

Page 45: ...HYUNDAI MOTOR CO REAR ROLL STOPPER 1 Remove the rear roll stopper from the subframe 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58...

Page 46: ...the stopper is correctly inserted into the inner pipe in order not to move 2 Install the stopper after making sure it is positioned correctly 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical Syste...

Page 47: ...FRONT ROLL STOPPER 1 Install the insulator in the correct angle A T 30 3 M T 14 3 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a...

Page 48: ...HYUNDAI MOTOR CO REAR ROLL STOPPER 1 Install the insulator in the correct angle A T 33 3 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07...

Page 49: ...shings into the cross member inner pipe align the arrow marks on the bushing with the lateral direction of the lateral member NOTE The front and rear cross member mounting bushings are directional Be...

Page 50: ...ember Arrow Mark 1 Of 2 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a m Page 50 2011 Mitchell Repai...

Page 51: ...positioned parallel to the lateral member of the cross member Be sure that the installation direction of the bushings do not deviate 3 from the lateral direction of the lateral member when they are in...

Page 52: ...peed manual transmission disconnect the select control valve connector 5 Disconnect the connectors for the alternator harness and the oil pressure gauge wiring 6 Drain the engine coolant 2002 Hyundai...

Page 53: ...ide 13 For vehicles with manual transmission remove the control cable from the transmission 14 For vehicles with automatic transmission remove the control cable from the transmission 15 Disconnect the...

Page 54: ...r Conditioner Compressor Courtesy of HYUNDAI MOTOR CO 17 Jack up the vehicle 18 Drain the transmission oil or fluid 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes...

Page 55: ...21 Remove the lower arm ball joint bolts and the stabilizer bar at the point where it is mounted to the lower arm 22 Remove the drive shafts from the transmission case NOTE Use wire to suspend the ex...

Page 56: ...enough to support the engine s weight while processing with the following steps 25 Remove the front roll stopper CAUTION Plug the axle holes of the transmission case to prevent entry of foreign mater...

Page 57: ...Courtesy of HYUNDAI MOTOR CO 26 Separate the rear roll stopper 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a m Page 57 2011 Mit...

Page 58: ...Remove the engine mounting insulator bolts 28 Remove the engine mounting bracket from the engine 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2...

Page 59: ...mporarily hold it in the raised position 30 Remove the caps from the inside of the right fender shield and remove the transaxle mount bracket bolts CAUTION Check that all cables hoses harnesses connec...

Page 60: ...transmission side downward lift the engine and transmission assembly up and out of the vehicles MAIN MOVING SYSTEM CAM SHAFT COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC...

Page 61: ...isconnect the breather hose and the PCV hose 2 Remove the coolant pump pulley and crankshaft pulley 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero d...

Page 62: ...ve the timing belt from the camshaft sprocket 6 Loosen the center cover bolts and remove the center cover 7 Remove the ignition coil assembly 8 Loosen the cylinder head cover bolts and remove the cyli...

Page 63: ...OR CO 9 Remove the camshaft sprocket 10 Remove the camshaft bearing caps and timing chain 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07...

Page 64: ...e camshaft journals for wear If the journals are badly worn replace the camshaft 2 Check the cam lobes for damage If the lobe is damaged or worn excessively replace the camshaft 2002 Hyundai Accent GL...

Page 65: ...3 Check the cam surface for abnormal wear or damage and replace if necessary 4 Check each bearing for damage If the bearing surface is excessively damaged replace the cylinder head assembly or camsha...

Page 66: ...threads are worn replace 2 Check the oil seal lip contacting surface of the camshaft If it is worn replace the camshaft 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent vie...

Page 67: ...2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a m Page 67 2011 Mitchell Repair Information Company LLC...

Page 68: ...ith engine oil hold A and press B by hand If B moves replace the HLA For other specific troubleshooting regarding HLA refer to Fig 64 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1...

Page 69: ...hecking HLA Hydraulic Lash Adjuster 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a m Page 69 2011 Mitchell Repair Information Com...

Page 70: ...I MOTOR CO TIMING CHAIN Check the bushing and plate of timing chain for wear Replace if wear is severe 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrer...

Page 71: ...LA 2 Align the camshaft timing chain with intake timing chain sprocket and exhaust timing chain sprocket as shown 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 1...

Page 72: ...MOTOR CO 3 Install the camshaft after lubricating the camshaft journals with engine oil 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 1...

Page 73: ...caps The markings on the caps are for intake exhaust identification I Intake camshaft E Exhaust camshaft 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febr...

Page 74: ...o the specified torque in two or three steps as shown Tightening torque Bearing cap bolt 12 14 Nm 120 140 kg cm 9 10 lb ft 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent...

Page 75: ...Be sure to apply engine oil to the oil seal lip Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is fully seated 2002 Hyundai Acc...

Page 76: ...procket bolts to the specified torque Tightening torque Camshaft sprocket bolt 80 100 Nm 800 1000 kg cm 59 74 lb ft 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes...

Page 77: ...ton in the No 1 cylinder to top dead center on the compression stroke 9 Install the cylinder head cover Tightening torque Cylinder head cover bolts 8 10 Nm 80 100 kg cm 6 7 lb ft 2002 Hyundai Accent G...

Page 78: ...CO 10 Install the spark plug cables ignition coil assembly and cylinder head center cover 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07...

Page 79: ...elt tensioner pulley 12 Install the timing belt cover Tightening torque Timing belt cover 8 10 Nm 80 100kg cm 6 7 lb ft 13 Install the coolant pump pulley and crankshaft pulley CRANK SHAFT COMPONENTS...

Page 80: ...nnecting rod caps 4 Remove the main bearing caps and remove the crank shaft 5 Remove the crankshaft position sensor wheel INSPECTION CRANKSHAFT CAUTION Mark the main bearing caps to permit reassembly...

Page 81: ...onnecting rod bearing 4 Measure the clearance by the value that subtract the diameter of journal and pin and the thickness of bearing from the diameter of bore Connecting rod bearing oil clearance 0 0...

Page 82: ...ournals 3 Install bearing caps and tighten cap bolts to the specified torque in the following sequence center No 2 NOTE 1 Measure the depth of the top of sensor wheel tooth and the cylinder block moun...

Page 83: ...directed toward the crank pulley side of engine Cap numbers must be correct Tightening torque Main bearing cap bolt 55 6Nm 550 600kg cm 41 44lb ft Connecting rod cap bolt 32 35Nm 320 350 kg cm 24 26l...

Page 84: ...Standard value Crankshaft end play 0 05 0 175 mm 0 0019 0 0068 in 5 Install the oil seal in the crankshaft rear oil seal case Use the Special Tool Crankshaft Rear Oil Seal Installer 09231 21000 as sh...

Page 85: ...te and tighten the bolts 7 Install the connecting rod caps 8 Install the flywheel front case oil pan and timing belt FLY WHEEL COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DO...

Page 86: ...f the flywheel for damage and wear Replace the flywheel if excessively damaged or worn 2 Check the clutch disc contacting surface of the flywheel for runout Standard value Flywheel run out 0 1 mm 0 00...

Page 87: ...Flywheel bolt 120 130Nm 1200 1300kg cm 89 96lb ft PISTON COMPONENTS Fig 79 Piston Components Courtesy of HYUNDAI MOTOR CO DISASSEMBLY 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1...

Page 88: ...assembly toward the top of the cylinder CAUTION Keep the bearings in order with their corresponding connecting rods according to cylinder numbers for proper reassembly 2002 Hyundai Accent GL 2002 ENG...

Page 89: ...upport fixture with fork inserts guides adapters an installer and a remover The piston is supported in the support fixture while the pin is being installed or removed Guides help position the pin as i...

Page 90: ...side and set the assembly into the support fixture with the pin guide facing down NOTE The pin guide should be centered on the connecting rod through the piston If assembled correctly the pin guide w...

Page 91: ...little end Continue pressing until the pin guide falls free and the installer tool seats against the top of the arch CAUTION Do not exceed 1250 500 kg 2765 1102 lb of force when the installing tool se...

Page 92: ...wear Replace the defective rings When the piston requires replacement its rings should also be replaced 3 Check that the piston pin fits in the piston pin hole Replace any piston and pin assembly tha...

Page 93: ...angles in the cylinder wall by gently pressing it down with a piston Measure the gap with a feeler gauge If the gap exceeds the service limit replace the piston ring Piston ring end gap Standard dimen...

Page 94: ...in O S 100 NOTE The mark can be found on the upper side of the ring next to the end 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58...

Page 95: ...g Piston Rings Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 58 a m Page 95 2011 Mitchell Repair Informa...

Page 96: ...re on the same side 2 Replace the connecting rod if it is damaged at either end of the thrust faces If it has a stratified wear in or if the surface of the inside diameter of the small end is severely...

Page 97: ...stall the spacer Fig 87 Installing Spacer Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 97 2...

Page 98: ...and press down with a finger on the portion to be inserted into the groove as illustrated 3 Install the lower side rail by the same procedure described in Step 2 CAUTION Do not use a piston ring expan...

Page 99: ...the piston and piston grooves 5 Using a piston ring expander install the No 2 piston ring 6 Install the No 1 piston ring 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent v...

Page 100: ...ble Make sure that the gaps are not positioned in the thrust and pin directions 8 Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder 2002 Hyundai Accent GL 2...

Page 101: ...r holding the bearing in place are on the same side 13 When assembling bolts should be fastened by the angle torque controlled method as the following 1 Apply oil to the thread of nuts and spot areas...

Page 102: ...0 0157 in 15 Install the oil screen 16 Install the oil pan 17 Install the cylinder head COOLING SYSTEM ENGINE COOLANT HOSE PIPES COOLING SYSTEM times 2002 Hyundai Accent GL 2002 ENGINE Engine Mechani...

Page 103: ...ose Pipes Courtesy of HYUNDAI MOTOR CO COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 103 2011 Mitchell Repair...

Page 104: ...inlet pipe end wet the O ring with coolant and insert the coolant inlet pipe NOTE 1 Do not apply oil or grease to the coolant pipe O ring 2 Keep the coolant pipe connections free of sand dust etc 3 In...

Page 105: ...it with a new part Fig 94 Identifying Coolant Pump Inlet Pipe Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07...

Page 106: ...Remove the coolant pump assembly from the cylinder block INSPECTION 1 Check each part for cracks damage or wear and replace the coolant pump assembly if necessary 2 Check the bearing for damage abnor...

Page 107: ...2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 107 2011 Mitchell Repair Information Company LLC...

Page 108: ...20 27Nm 200 270kg cm 15 20 lb ft Fig 97 Locating Coolant Pump Bolts Courtesy of HYUNDAI MOTOR CO 3 Install the timing tensioner and timing belt Adjust the timing belt tension 4 Install the timing bel...

Page 109: ...y of HYUNDAI MOTOR CO DISASSEMBLY 1 Disconnect the radiator fan motor connector 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m...

Page 110: ...ounting bolts 7 Remove the radiator together with the fan motor 8 Remove the fan motor from the radiator INSPECTION 1 Check the radiator for bent broken or plugged fins 2 Check the radiator for corros...

Page 111: ...Fan Operation Courtesy of HYUNDAI MOTOR CO 2 Check that abnormal noises are not produced while the motor is turning REASSEMBLY 1 Fill the radiator and reservoir tank with clean coolant mixture 2 Run t...

Page 112: ...1 Radiator Cap Components Courtesy of HYUNDAI MOTOR CO INSPECTION 1 Check the radiator cap for damage cracks and deterioration 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Acc...

Page 113: ...mp the tester until the pointer stabilizes 4 If the pointer stays constant for 10 seconds at a point exceeding the service limit the radiator cap is good 2002 Hyundai Accent GL 2002 ENGINE Engine Mech...

Page 114: ...o Radiator Cap Courtesy of HYUNDAI MOTOR CO THERMOSTAT COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 114 2011...

Page 115: ...ket 3 Remove the thermostat 4 Immerse thermostat in hot coolant to check proper valve opening temperature Replace if necessary Valve opening temperature 82 C 177 F Full opening temperature 95 C 205 F...

Page 116: ...ange Resistance At 20 C 68 F 2 31 2 59 kg REASSEMBLY 1 Check that the flange of the thermostat is correctly seated in the socket of the thermostat housing 2 Install a new gasket and the coolant inlet...

Page 117: ...0 40 Nm 200 400 kg cm 15 30 lb ft LUBRICATION SYSTEM OIL PUMP COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 11...

Page 118: ...belt 2 Remove all the oil pan bolts 3 Remove the oil pan 4 Remove the oil screen 5 Remove the front case assembly 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes...

Page 119: ...ge Replace as necessary 2 Check the front oil seal for worn or damaged lips Replace if defective OIL PAN AND OIL SCREEN 1 Check the oil pan for failure damage or cracks Replace if defective 2 Check th...

Page 120: ...027 in Side clearance Outer gear 0 04 0 09 mm 0 0016 0 0035 in Inner gear 0 04 0 085 mm 0 0016 0 0033 in Fig 108 Measuring Clearance Between Outer Gear Front Case Courtesy of HYUNDAI MOTOR CO 3 Check...

Page 121: ...arance On Pump Rotor Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 121 2011 Mitchell Repair...

Page 122: ...OR CO RELIEF VALVE AND SPRING 1 Check sliding condition of the relief valve inserted in the front case 2 Inspect for distorted or broken relief valve spring 2002 Hyundai Accent GL 2002 ENGINE Engine M...

Page 123: ...Use an ohmmeter to check the continuity between the terminal and the body If there is no continuity replace the oil pressure switch 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6...

Page 124: ...the fine wire is pushed replace the switch 3 If there is no continuity when a 50 kPa 7 psi vacuum is applied through the oil hole the switch is operating properly Check for air leaks If air does leak...

Page 125: ...ner and outer gears are installed in the same direction as shown 2 Install the oil pump cover and tighten the bolts to the specified torque After the bolts have been tightened check to ensure that the...

Page 126: ...4 Inspecting Oil Pump Body Clearance Courtesy of HYUNDAI MOTOR CO FRONT CASE 1 Install the front case assembly with a new gasket and tighten the bolts to the specified torque Tightening torque 20 27 N...

Page 127: ...f HYUNDAI MOTOR CO OIL SEAL 1 Using the special tool Crankshaft oil seal guide 09214 21100 install the oil seal 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19...

Page 128: ...I MOTOR CO 2 Using the special tool Crankshaft front oil seal installer 09214 21000 install the oil seal 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febr...

Page 129: ...r block 5 Apply sealant into the groove of the oil pan flange as shown CAUTION Apply sealant approx 4mm 0 16 in in thickness After application of sealant do not exceed 15 minutes before installing the...

Page 130: ...kg cm 7 9 lb ft INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD Fig 118 Applying Sealant Into Groove Of Oil Pan Flange Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical Syst...

Page 131: ...he cylinder head 3 Remove the exhaust manifold gasket INSPECTION EXHAUST MANIFOLD 1 Check for damage or cracking 2 Check for damage or cracking of welding between exhaust manifold and converter REASSE...

Page 132: ...ke Manifold Components Courtesy of HYUNDAI MOTOR CO CAUTION Replace the exhaust manifold gasket and lock nut when reassembling 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Acc...

Page 133: ...throttle body 3 Remove the accelerator cable 4 Remove the P C V hose and brake booster vacuum hoses 5 Disconnect the vacuum hose connections ISA and TPS connector 2002 Hyundai Accent GL 2002 ENGINE E...

Page 134: ...take manifold 8 Remove the intake manifold assembly and gasket 9 Disconnect the fuel injector harness connector 10 Remove the delivery pipe with the fuel injectors CAUTION Be careful not to drop the i...

Page 135: ...damage or cracking of any part INSTALLATION 1 Replace the intake manifold gasket and install the intake manifold CAUTION Be careful not to drop the injectors when removing the delivery pipe 2002 Hyun...

Page 136: ...ct the high pressure fuel hose connection 6 Install the P C V hose and brake booster vacuum hose 7 Install the intake air hose to the throttle body 8 Install the accelerator cable 9 Connect the ISA an...

Page 137: ...rom the center muffler CAUTION Before removing or inspecting the exhaust system ensure that the exhaust system has cooled sufficiently 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC...

Page 138: ...urtesy of HYUNDAI MOTOR CO 2 Remove the rubber hangers and remove the main muffler 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a...

Page 139: ...OR CO CENTER MUFFLER 1 Remove the center muffler assembly from the main muffler and front exhaust pipe 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrer...

Page 140: ...XHAUST PIPE 1 Remove the front exhaust pipe clamp bolts and remove the front exhaust pipe nuts from the catalytic converter 2 Remove the front exhaust pipe and center muffler bolt 2002 Hyundai Accent...

Page 141: ...center exhaust pipe and the main muffler in that order 2 Tighten the parts securely Make sure there is no interference with any body components AIR CLEANER ACL COMPONENTS 2002 Hyundai Accent GL 2002...

Page 142: ...ure sensor harness 3 Remove the air intake hose at the air cleaner side 4 Remove the air cleaner cover and filter 5 Remove the air cleaner mounting bolts and remove the air cleaner 2002 Hyundai Accent...

Page 143: ...over or filter for distortion corrosion or damage 2 Check the air duct for damage 3 Check the resonator for distortion or damage 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L A...

Page 144: ...mination or damage If the filter is slightly restricted remove the dust and other contaminants by blowing compressed air from the upper side through the filter 2002 Hyundai Accent GL 2002 ENGINE Engin...

Page 145: ...n or damage INSTALLATION Install the air cleaner assembly following the reverse order of removal CYLINDER HEAD ASSEMBLY CYLINDER HEAD COMPONENTS 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical Sy...

Page 146: ...134 Cylinder Head Components 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 146 2011 Mitchell Repair Information Company...

Page 147: ...MPONENTS Fig 135 Valves Components Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 147 2011 Mi...

Page 148: ...1 remove the cylinder head bolts in the order shown in the illustration 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 12 59 a m Page 148...

Page 149: ...Cylinder Head Bolts Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 149 2011 Mitchell Repair...

Page 150: ...er Lock Courtesy of HYUNDAI MOTOR CO 3 Remove the valve stem seals with pliers NOTE Arrange these parts so that they can be reinstalled in their original positions NOTE Do not reuse the valve stem sea...

Page 151: ...d replace the cylinder head 2 Remove scale sealing compound and carbon deposits completely After cleaning the oil passages apply compressed air to verify that the passages are not clogged 2002 Hyundai...

Page 152: ...either replace the cylinder head or machine the cylinder head matching surface lightly Flatness of cylinder head gasket surface Standard Less than 0 03mm 0 0012 in Limit 0 2 mm 0 008 in VALVES 1 Usin...

Page 153: ...ection must be limited to a minimum Also resurface the valve face Replace the valve if the margin has decreased to less than the service limit Margin Standard Intake 1 1 mm 0 043 in Exhaust 1 3 mm 0 0...

Page 154: ...Head For Distortion Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 154 2011 Mitchell Repair I...

Page 155: ...of square replace it Valve spring Standard Free height 44 mm 1 7323 in Load 21 6kg 35 mm 47 6 lb 1 0709 in 45 1 kg 27 2 mm 16 lb 1 0709 in Out of square 1 5 or less 100 Limit Free height 1 0 mm 0 039...

Page 156: ...e Height Squareness Courtesy of HYUNDAI MOTOR CO VALVE GUIDES 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 156 2011 Mitc...

Page 157: ...in Limit Intake 0 1mm 0 0040 in Exhaust 0 15mm 0 0059 in Fig 143 Checking Valve Stem To Guide Clearance Courtesy of HYUNDAI MOTOR CO RECONDITIONING VALVE SEAT Check the valve seat for overheating and...

Page 158: ...at grinder or cutter The valve seat contact width should be within specifications and centered on the valve face After reconditioning the valve and valve seat should be lapped lightly with a lapping c...

Page 159: ...e specified oversize hole diameter of the new valve seat ring 3 Heat the cylinder head to about 250 C 480 F and press fit an oversize seat ring for the bore in the cylinder head 4 Using lapping compou...

Page 160: ...2000 A B withdraw the old valve guide toward the bottom of cylinder head 2 Recondition the valve guide hole so that it can match the newly press fitted oversize valve guide 2002 Hyundai Accent GL 2002...

Page 161: ...guide must be press fitted from the upper side of the cylinder head 4 After the valve guide is press fitted insert a new valve and check for proper the clearance 2002 Hyundai Accent GL 2002 ENGINE Eng...

Page 162: ...valve Insert the valve into the valve guide Avoid pushing the valve into the seal by force After inserting the valve check that it moves smoothly NOTE 1 Clean each part before assembly 2 Apply engine...

Page 163: ...prings so that the side coated with enamel faces toward the valve spring retainer and then install the retainer 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19...

Page 164: ...install the retainer locks After installing the valves ensure that the retainer locks are correctly in place before releasing the valve spring compressor 2002 Hyundai Accent GL 2002 ENGINE Engine Mec...

Page 165: ...e surface with the identification mark faces toward the cylinder head 8 Tighten the bolts to the specified torque in the sequence shown NOTE When the spring is compressed Check that the valve stem sea...

Page 166: ...2 Tightening Cylinder Head Bolts 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 166 2011 Mitchell Repair Information Compa...

Page 167: ...onents Courtesy of HYUNDAI MOTOR CO DISASSEMBLY 1 Loosen the coolant pump pulley bolt 2 Loosen the alternator bolt 3 Remove the coolant pump pulley and belt 4 Remove the crankshaft pulley 2002 Hyundai...

Page 168: ...154 Removing Timing Belt Cover Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 168 2011 Mitch...

Page 169: ...bolts Remove the crankshaft sprocket and flange 11 Remove the timing belt tensioner INSPECTION SPROCKETS TENSIONER PULLEY AND IDLER PULLEY NOTE If the timing belt is reused mark with an arrow to indic...

Page 170: ...ioner Pulley Idler Pulley Movement Courtesy of HYUNDAI MOTOR CO TIMING BELT 1 Check the belt for oil or dust deposits Replace if necessary Small deposits should be wiped away with a dry cloth or paper...

Page 171: ...For Timing Belt Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 171 2011 Mitchell Repair Info...

Page 172: ...w Conditions 1 Of 2 Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 172 2011 Mitchell Repair I...

Page 173: ...procket as shown Pay close attention to their mounting directions Tightening torque Crankshaft sprocket bolt 140 150Nm 1400 1500kg cm 103 111lb ft 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical...

Page 174: ...idler and tighten the idler bolt to the specified torque Tightening torque Idler bolt 43 55Nm 430 550kg cm 32 41lb ft 4 Align the timing marks of the camshaft sprocket and crankshaft sprocket with th...

Page 175: ...amshaft Sprockets Courtesy of HYUNDAI MOTOR CO 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 175 2011 Mitchell Repair Inf...

Page 176: ...rily tighten the bolts Next temporarily tighten the tensioner long hole side washer and bolts Install the bottom end of the spring against the front case as shown in the illustration 2002 Hyundai Acce...

Page 177: ...ket When the timing belt is installed on the camshaft sprocket make sure that the tension side is tight Then check to ensure that when the tension side is tightened by turning the camshaft sprocket in...

Page 178: ...Nm 200 270kg cm 15 20lb ft 11 Then recheck the belt tension Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force approx 49N 11lb the...

Page 179: ...Courtesy of HYUNDAI MOTOR CO 12 Install the timing belt cover 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 179 2011 Mit...

Page 180: ...t Cover Courtesy of HYUNDAI MOTOR CO Tightening torque 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System DOHC 1 6L Accent viernes 19 de febrero de 2021 07 13 00 a m Page 180 2011 Mitchell Re...

Page 181: ...t 140 150 Nm 1400 1500kg cm 103 111lb ft 14 Install the fan belt and adjust the belt tension 15 Install the water pump pulley 16 Install V belt and adjust the belt tension Fig 167 Installing V Belt Co...

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