Hyundai Elantra AD: General Information - Engine Mechanical System - Hyundai Elantra AD 2017-2020 Service ManualHyundai Elantra AD: General Information

Specifications

Specifications

Description
Specifications
Limit
General
Type
In-line, DOHC

Number of cylinders
4

Bore
81.0 mm (3.1890 in.)

Stroke
97.0 mm (3.8189 in.)

Total displacement
1999 cc (121.99 cu.in.)

Compression ratio
12.5±0.2 : 1

Firing order
1-3-4-2

Valve timing
Intake valve
Open
[BTDC 38° ~ ATDC 2°(initial position)] ~ [ATDC 42°]

Close
[ABDC 43° ~ ABDC 83°(initial position)] ~ [ABDC 123°]

Exhaust valve
Open
BBDC 54° ~ ABDC 6°

Close
ATDC 1° ~ ATDC 61°

Camshaft
Cam height
Intake
39.0 mm (1.5354 in.)

Exhaust
38.66 mm (1.5220 in.)

Journal outer diameter
Intake
No.1: 35.959 ~ 35.975 mm
(1.41571 ~ 1.41634 in.)

No.2,3,4,5: 22.959 ~ 22.975 mm
(0.90390 ~ 0.90453 in.)

Exhaust
No.1: 35.959 ~ 35.975 mm
(1.41571 ~ 1.41634 in.)

No.2,3,4,5: 22.959 ~ 22.975 mm
(0.90390 ~ 0.90453 in.)

Bearing oil clearance
Intake
No.1: 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)

No.2,3,4,5: 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)


Exhaust
No.1: 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)


No.2,3,4,5: 0.032 ~ 0.062 mm
(0.00126 ~ 0.00244 in.)


End play
0.10 ~ 0.19 mm (0.0039 ~ 0.0075 in.)

Valve
Valve length
Intake
102.22 mm (4.0244 in.)
101.97 mm (4.0146 in.)
Exhaust
104.04 mm (4.0961 in.)
103.79 mm (4.0862 in.)
Stem outer diameter
Intake
5.465 ~ 5.480 mm (0.21516 ~ 0.21575 in.)

Exhaust
5.458 ~ 5.470 mm (0.21488 ~ 0.21535 in.)

Face angle
45.25° ~ 45.75°

Thickness of valve head
(margin)
Intake
1.41 ~ 1.71 mm (0.0555 ~ 0.0673 in.)

Exhaust
1.55 ~ 1.85 mm (0.0610 ~ 0.0728 in.)

Valve stem to valve guide clearance
Intake
0.020 ~ 0.047 mm (0.00079 ~ 0.00185 in.)

Exhaust
0.030 ~ 0.054 mm (0.00118 ~ 0.00213 in.)

Valve guide
Length
Intake
43.8 ~ 44.2 mm (1.7244 ~ 1.7402 in.)

Exhaust
43.8 ~ 44.2 mm (1.7244 ~ 1.7402 in.)

Inner diameter
Intake
5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)

Exhaust
5.500 ~ 5.512 mm (0.21654 ~ 0.21701 in.)

Valve seat
Width of seat contact
Intake
1.05 ~ 1.35 mm (0.0413 ~ 0.0532 in.)

Exhaust
1.35 ~ 1.65 mm (0.0532 ~ 0.0650 in.)

Seat angle
Intake
44° 45' ~ 45° 6'

Exhaust
44° 45' ~ 45° 6'

Valve spring
Free length
45.93 mm (1.8083 in.)

Load
19.6 ± 1.0 kg / 37.0 mm
(43.21 ± 2.20 lb / 1.4567 in.)

45.7 ± 1.8 kg / 27.0 mm
(100.75 ± 3.97 lb / 1.0630 in.)

Out of squareness
Less than 1.5°

Cylinder head
Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area

Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) x 100 mm (3.9370 in.)

Flatness of manifold mounting surface
Intake
Less than 0.10 mm (0.0039 in.)

Exhaust
Less than 0.10 mm (0.0039 in.)

Piston
Piston outer diameter
80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)

Piston to cylinder clearance
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)

Ring groove width
No. 1 ring
1.030 ~ 1.050 mm (0.04055 ~ 0.04134 in.)

No. 2 ring
1.230 ~ 1.250 mm (0.04843 ~ 0.04921 in.)

Oil ring
2.010 ~ 2.025 mm (0.07913 ~ 0.07972 in.)

Piston ring
Side clearance
No. 1 ring
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)

No. 2 ring
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)

Oil ring
0.020 ~ 0.055 mm (0.00079 ~ 0.00216 in.)

End gap
No. 1 ring
0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)

No. 2 ring
0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)

Oil ring
0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in.)

Piston pin
Piston pin outer diameter
19.997 ~ 20.000 mm (0.78728 ~ 0.78740 in.)

Piston pin hole inner diameter
20.004 ~ 20.009 mm (0.78756 ~ 0.78775 in.)

Piston pin hole clearance
0.004 ~ 0.012 mm (0.00016 ~ 0.00047 in.)

Connecting rod small end hole inner diameter
20.007 ~ 20.015 mm (0.78768 ~ 0.78799 in.)

Piston pin-to-connecting rod bushing oil clearance
0.007 ~ 0.018 mm (0.00028 ~ 0.00071 in.)

Connecting rod
Connecting rod big end inner diameter
48.000 ~ 48.018 mm (1.88976 ~ 1.89047 in.)

Connecting rod bearing oil clearance
0.024 ~ 0.042 mm (0.00094 ~ 0.00165 in.)

Side clearance
0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.)

Crankshaft
Main journal outer diameter
54.942 ~ 54.960 mm (2.16307 ~ 2.16378 in.)

Pin journal outer diameter
44.954 ~ 44.972 mm (1.76984 ~ 1.77055 in.)

Main bearing oil clearance
0.016 ~ 0.034 mm (0.00063 ~ 0.00134 in.)

End play
0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)

Cylinder block
Cylinder bore
81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)

Flatness of gasket surface
Less than 0.05 mm (0.0020 in.) for total area

Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) x 100 mm (3.9370 in.)

Engine oil
Oil quantity
Total
4.5 L (1.19 U.S.gal., 4.76 U.S.qt., 3.96 lmp.qt.)
When replacing a short engine or block assembly
Oil pan
3.7 L (0.98 U.S.gal., 3.91 U.S.qt., 3.26 lmp.qt.)

Drain and refill
4.0 L (1.06 U.S.gal., 4.23 U.S.qt., 3.52 lmp.qt.)
Including oil filter
Oil grade
Specifications
5W-20 / API SM& ILSAC GF-4 (or above) / ACEA A5 (or above)
  
API SL, ILSAC GF-3, ACEA A3 Class engine oil can be used if the recommended engine oil is not available.
Refer to the "Lubrication System" for recommended SAE viscosity number.

Oil pressure (at 1,000rpm)
90.22 kPa (0.92 kgf/cm?, 13.09 psi) or above
Oil temperature (oil pan): 110±2°C (230±35.6°F)
Oil Pump
Relief valve opening pressure
500.14 ~ 600.16 kPa (5.10 ~ 6.12 kgf/cm?,
72.54 ~ 87.05 psi) (5~6bar)

Side clearance
0.040 ~ 0.090 mm (0.00157 ~ 0.00354 in.)

Body clearance
0.200 ~ 0.292 mm (0.00787 ~ 0.01149 in.)

Guide clearance
0.030 ~ 0.075 mm (0.00118 ~ 0.00295 in.)

Cooling system
Cooling method
Forced circulation with cooling fan

Coolant quantity
Approx. 6.6 L (1.66 U.S.gal., 6.97 U.S.qt., 5.81 lmp.qt.)

Electric thermostat (ECT)
Type
Wax pellet type

Opening
temperature
100±2°C (212±35.6°F)

Full opening valve lift / temperature
More than 8 mm (0.3 in.) / 115°C (239°F)

Radiator cap
Main valve opening pressure
93.16 ~ 122.58 kPa
(0.95 ~ 1.25 kgf/cm?, 13.51 ~ 17.78 psi)

Vacuum valve opening pressure
0 ~ 6.86 kPa (0 ~ 0.07 kgf/cm?, 0 ~ 1.00 psi)


Liquid Gasket

Location
Product
Mating surface of timing chain cover
Threebond 1217H or equivalent
Front area of mating surface between cam carrier and cylinder head
Front area of mating surface between cylinder block and head
Upper area of mating surface between timing chain cover and cam carrier
Front upper area of cylinder block
Front upper area of cylinder head gasket
Lower area of cam carrier
Lower area of cylinder block
Mating surface of oil pan
Mating surface of oil pressure switch
THREEBOND 2403

Tightening Torques

Item
N.m
kgf.m
lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Engine mounting support bracket to engine mounting insulator fixing nut
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Engine mounting support bracket to engine support bracket fixing bolt
58.8 ~ 73.5
6.0 ~ 7.5
43.4 ~ 54.2
Engine mounting support bracket to engine support bracket fixing nut
58.8 ~ 73.5
6.0 ~ 7.5
43.4 ~ 54.2
Transaxle mounting bracket to body fixing bolt
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Transaxle mounting bracket  to transaxle mounting support bracket fixing bolt
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Roll rod bracket to sub frame fixing bolt
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Roll rod bracket to roll rod support bracket fixing bolt & nut
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Timing system
Crankshaft pulley bolt
196.1 ~ 205.9
20.0 ~ 21.0
144.7 ~ 151.9
Timing chain cover service plug bolt
29.4 ~ 39.2
3.0 ~ 4.0
21.7 ~ 28.9
Timing chain cover bolt (M10x55)
39.2 ~ 49.0
4.0 ~ 5.0
28.9 ~ 36.2
Timing chain cover bolt (M10x85)
39.2 ~ 49.0
4.0 ~ 5.0
28.9 ~ 36.2
Timing chain cover bolt - Seal bolt (M6x38)
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain cover bolt - Seal bolt (M8x50)
19.6 ~ 23.5
2.0 ~ 2.4
14.5 ~ 17.4
Timing chain cover bolt (M8x50)
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Timing chain cover bolt (M8x28)
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Timing chain tensioner bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain tensioner arm bolt
18.6 ~ 22.6
1.9 ~ 2.3
13.7 ~ 16.6
Timing chain guide bolt
18.6 ~ 22.6
1.9 ~ 2.3
13.7 ~ 16.6
Cylinder head
Engine cover mounting bolt
7.8 ~ 9.8
0.8 ~ 1.0
5.8 ~ 7.2
Ignition coil bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder head cover bolt
[3.9~5.9] + [7.8~9.8]
[0.4~0.6] + [0.8~1.0]
[2.9~4.3] + [5.8~7.2]
Injector & rail assembly bolt
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
CVVT bolt (LH/RH)
64.7 ~ 76.5
6.6 ~ 7.8
47.7 ~ 56.4
Camshaft bearing cap bolt (M6)
11.8 ~ 13.7
1.2 ~ 1.4
8.7 ~ 10.1
Camshaft bearing cap bolt (M8)
18.6 ~ 22.6
1.9 ~ 2.3
13.7 ~ 16.6
Cam carrier bolt
18.6 ~ 22.6
1.9 ~ 2.3
13.7 ~ 16.6
Cylinder head bolt
[32.4~36.3] + [90~95°] + [90~95°]
[3.3~3.7] + [90~95°] + [90~95°]
[23.9~26.8] + [90~95°] + [90~95°]
Engine hanger bolt (Front/Rear)
34.3 ~ 39.2
3.5 ~ 4.0
25.3 ~ 28.9
Camshaft position sensor (LH/RH)
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Oil control valve (OCV) bolt (LH/RH)
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder block
Drive plate bolt
117.7 ~ 127.5
12.0 ~ 13.0
86.8 ~ 93.9
Connecting rod bearing cap bolt
[17.7~21.6] + [103~107°]
[1.8~2.2] + [103~107°]
[13.0~15.9] + [103~107°]
Lower crankcase bolt
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Main bearing cap bolt
[27.5~31.4] + [120~125°]
[2.8~3.2] + [120~125°]
[20.3~23.1] + [120~125°]
Crankshaft position sensor bolt
10.8 ~ 11.8
1.1 ~ 1.2
8.0 ~ 8.7
Knock sensor
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Lubrication system
Oil drain plug
34.3 ~ 44.1
3.5 ~ 4.5
25.3 ~ 32.5
Oil filter
11.8 ~ 15.7
1.2 ~ 1.6
8.7 ~ 11.6
Oil pan bolt
11.8 ~ 13.7
1.2 ~ 1.4
8.7 ~ 10.1
Oil screen bolt
19.6 ~ 26.5
2.0 ~ 2.7
14.5 ~ 19.5
Oil screen nut
11.8 ~ 13.7
1.2 ~ 1.4
8.7 ~ 10.1
Oil pressure switch
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cooling system
Water pump pulley bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Water pump bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Water inlet fitting nut
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Water temperature control assembly bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Heater pipe bolt
19.6 ~ 23.5
2.0 ~ 2.4
14.5 ~ 17.4
Intake and exhaust system
Air intake hose clamp bolt
2.9 ~ 4.9
0.3 ~ 0.5
2.2 ~ 3.6
Air cleaner assembly bolt
7.8 ~ 9.8
0.8 ~ 1.0
5.8 ~ 7.2
Electronic throttle control (ETC) module bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Intake manifold stay bolt
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Intake manifold bolt
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Intake manifold nut
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Exhaust manifold heat protector bolt
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Exhaust manifold stay bolt
39.2 ~49.0
4.0 ~ 5.0
28.9 ~ 36.2
Exhaust manifold nut
34.3 ~ 39.2
3.5 ~ 4.0
25.3 ~ 28.9
Muffler nut
39.2 ~ 58.8
4.0 ~ 6.0
28.9 ~ 43.4

Repair procedures

Compression Pressure Inspection
  
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.
1. Warm up and stop engine.

Allow the engine to warm up to normal operating temperature.

2. Disconnect the injector connectors (A).

3. Remove spark plugs.

(Refer to Engine Electrical System - "Spark Plug")

4. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.

(2) Fully open the throttle.
(3) While cranking the engine, measure the compression pressure.
  
Always use a fully charged battery to obtain engine speed of 200 rpm or more.
(4) Repeat steps (1) through (3) for each cylinder.
  
This measurement must be done in as short a time as possible.

Compression pressure:

1,275 kPa (13.0 kgf/cm?, 185 psi)

Minimum pressure:

1,128 kPa (11.5 kgf/cm?, 164 psi)

Difference between each cylinder:

100 kPa (1.0 kgf/cm?, 15 psi) or less


(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (1) through (3) for cylinders with low compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
5. Install the other parts reverse order of removal.
6. Some DTCs may exist after the inspection test and may need to be manually cleared with GDS.

Troubleshooting

Troubleshooting

Symption
Suspect area
Remedy
Engine misfire with abnormal internal lower engine noises
Worn crankshaft bearings
Loose or out of specification engine flywheel
Replace the crankshaft and bearings as required.
Repair or replace the flywheel as required.
Worn piston rings
(Oil consumption may or may not cause the engine to misfire.)
Inspect the cylinder for a loss of compression.
Repair or replace as required.
Worn crankshaft thrust bearings
Replace the crankshaft and bearings as required
Engine misfire with abnormal valve train noise
Stuck valves
(Carbon buidup on the valve stem)
Repair or replace as required.
Excessive worn or mis-aligned timing chain
Replace the timing chain and sprocket as required.
Worn camshaft lobes
Replace the camshaft.
Engine misfire with coolant consumption
Faulty cylinder head gasket or other damage to the cylinder head and engine block cooling system
Coolant consumption may or may not cause the engine to overheat
Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket.
Repair or replace as required.
Engine misfire with excessive oil consumption
Worn valves, guides and/or valve stem oil seals
Repair or replace as required.
Worn piston rings
(Oil consumption may or may not cause the engine to misfire)
Inspect the cylinder for a loss of compression.
Repair or replace as required.
Engine noise on start-up, but only lasting a few seconds
(Check and compare with known good vehicle to determine normal condition.)
Incorrect oil viscosity
Drain the oil.
Install the correct viscosity oil.
Worn crankshaft thrust bearing
Inspect the thrust bearing and crankshaft.
Repair or replace as required.
Upper engine noise, regardless of engine speed
Low oil pressure
Repair or replace as required.
Broken valve spring
Replace the valve spring.
Worn or dirty valve lifters
Replace the valve lifters.
Stetched or broken timing chain and/or damaged sprocket teeth
Replace the timing chain and sprockets.
Worn timing chain tensioner, if applicable
Replace the timing chain tensioner as required.
Worn camshaft lobes
Inspect the camshaft lobes.
Replace the camshaft as required.
Worn valve guides or valve stems
Inspect the valves and valve guides, then repair or replace as required.
Stuck valves (Carbon on the valve stem or valve seat may cause the valve to stay open.)
Inspect the valves and valve guides, then repair or replace as required.
Worn drive belt, idler, tensioner and bearing
Replace as required.
Lower engine noise, regardless of engine speed
Low oil pressure
Repair or required.
Loose or damaged flywheel
Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen
Inspect the oil pan.
Inspect the oil pump screen.
Repair or replace as required.
Oil pump screen loose, damaged or restricted
Inspect the oil pump screen.
Repair or replace as required.
Excessive piston-to-cylinder bore clearance
Inspect the piston, piston pin and cylinder bore.
Repair or replace as required.
Excessive piston pin-to-piston clearance
Inspect the piston, piston pin and the connecting rod.
Repair or replace as required.
Excessive connecting rod bearing clearance
Inspect the following components and repair or replace as required.
The connecting rod bearings.
The connecting rods.
The crankshaft pin journals.
Excessive crankshaft bearing clearance
Inspect the following components, and repair or replace as required.
The crankshaft bearings.
The crankshaft main journals.
The cylinder block
Incorrect piston, piston pin and connecting rod installation
Verify the piston pins and connecting rods are installed correctly.
Repair as required.
Engine noise under load
Low oil pressure
Repair or replace as required.
Excessive connecting rod bearing clearance
Inspect the following components and repair or replace as required:
The connecting rod bearings
The connecting rods
The crankshaft
Excessive crankshaft bearing clearance
Inspect the following components, and repair or replace as required:
The crankshaft bearings
The crankshaft main journals
The cylinder block
Engine is not cranked.
Crankshaft does not rotate.
Hydraulically locked cylinder
Coolant/antifreeze in cylinder
Oil in cylinder
Fuel in cylinder
1. Remove spark plugs and check for fluid.
2. Inspect for broken head gasket.
3. Inspect for cracked engine block or cylinder head.
4. Inspect for a sticking fuel injector and/or leaking fuel regulator.
Broken timing chain and/or timing chain gears
1. Inspect timing chain and gears.
2. Repair as required.
Material in cylinder
Broken valve
Piston material
Foreign material
1. Inspect cylinder for damaged components and/or foreign materials.
2. Repair or replace as required.
Seized crankshaft or connecting rod bearings
1. Inspect crankshaft and connecting rod bearing.
2. Repair as required.
Bent or broken connecting rod
1. Inspect connecting rods.
2. Repair as required.
Broken crankshaft
1. Inspect crankshaft.
2. Repair as required.

Special Service Tools

Special Service Tools

Tool (Number and name)
Illustration
Use
Crankshaft front oil seal installer
09231-2E000

Installation of the front oil seal
Valve stem seal installer
09222-2E000

Installation of the valve stem oil seal
Valve spring compressor
A : 09222-3K000
B : 09222-2A100

Removal and installation of the intake or exhaust valve
Crankshaft rear oil seal installer
A : 09214-2E000
B : 09231-H1100

Installation of the rear oil seal
Ring gear stopper
A : 09231-2B100
B : 09231-3N100

Removal and installation of crankshaft pulley
bolt.
Ring gear stopper
A : 09231-3D100
B : 09231-2W100

Removal and installation of crankshaft pulley
bolt.
Torque angle adapter
09221-4A000

Installation of bolts & nuts needing an angular method of adjustment
Oil pan remover
09215-3C000

Removal of oil pan
Must use this tool to separate the oil pan from the lower crankcase assembly without damage to the sealing surfaces
Tensioner stopper pin
09240-2E100

Holding compressed piston of tensioner
Oil filter wrench
09263-2E000

Removal and installation of oil filter

Engine And Transaxle Assembly
Engine Cover Repair procedures Removal and Installation 1. Remove the engine cover (A).    ...