Xe ô tô hyundai excel toàn tập hyundai excel - P13

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GENERAL 2

ENGINE MOUNTING 21

ENGINE AND TRANSMISSION ASSEMBLY 26

TIMING BELT TRAIN 30

ROCKER ARMS AND ROCKER SHAFT 36

CAMSHAFT 38

CYLINDER HEAD 42

VALVE AND VALVE SPRINGS 46

JET VALVE 52

FRONT CASE, OIL PUMP 56

PISTON AND CONNECTING ROD 6 1 CRANKSHAFT 66

FLYWHEEL 69

CYLlNDER BLOCK 70

OIL PRESSURE SWITCH 72

Intake valve duration

Exhaust valve duration

Jet valve duration

Warpage of lower face of head

Clearance with camshaft

Oversize rework dimension of valve seat hole

Intake 0.3 mm (0.012 in.)

0.6 mm (0.024 in.) Exhaust 0.3 mm (0.012 in.)

0.6 mm (0.024 in.) Oversize rework of valve guide hole

(both intake and exhaust)

0.05 mm (0.002 in.) 0.25 mm (0.010 in.) 0.50 mm (0.020 in.)

In-line OHV, OHC 4

75.5 mm (2.97 in.)

82 mm (3.23 in.) 1,468 cc (89.6 cu.in.) 9.4

1-3-4-2 Refer to emission control information label on car

Within 0.05 mm (0.002 in.) 0.05-0.09 mm (0.002-0.0035 in.)

0.1 mm (0.004 in.)

39.3-39.325 mm (1.5472-1.5482 in.) 39.6-39.625 mm (1.5590-1.5600in.) 34.3-34.325 mm (1.3504-1.3534 in.) 34.6-34.625 mm (1.3622-1.3632 in.)

13.05-13.068 mm (0.5135-0.5145 in.) 13.25-13.268 mm (0.5216-0.5224 in.) 13.50-13.518 mm (0.5315-0.5323 in.)

20-2

Valve seat insert

Width of seat contact

Out-of-roundness and taper of cylinder bore

Clearance with piston

Piston

O.D.

Oversize

38.1 mm (1.5000 in.) -0.5 mm (-0.020 in.) 38.2 mm (1.5039 in.) -0.5 mm (-0.020 in.) 0.05-0.20 mm (0.002-0.008 in.)

6.6 mm (0.26 in.) 6.6 mm (0.26 in.)

1.0 mm (0.039 in.) 0.7 mm (0.028 in.) 1.5 mm (0.059 in.) 1.0 mm (0.039 in.)

0.03-0.06 mm (0.0012-0.0024 in.) 0.10 mm (0.004 in.) 0.05-0.09 mm (0.0020-0.0035 in.) 0.15 mm (0.006 in.)

13.7-14.3 mm (0.5394-0.5630 in.) 0.05 mm, 0.25 mm, 0.50 mm (0.002 in., 0.010 in., 0.020 in.)

0.9-1.3 mm (0.035 in., 0.024 in.) 45°

0.3 mm, 0.6 mm (0.012 in., 0.024 in.)

44.6 mm (1.756 in.)

24 kg/27.3 mm (53 lb./1.469 in.)

36 mm (1.417 in.) 1.5° or less

4.300 mm (0.1693 in.) 45°

-1.0 mm (-0.039 in.)

+1 mm (+0.039 in.) 3°

29.60 mm (1.1654 in.) 3.5 kg/21.5 mm (5.5 lb/0.846 in.)

75.5 mm (2.972 in.) Within 0.02 mm (0.0008 in.) 0.02-0.04 mm (0.0008-0.0016 in.)

75.5 mm (2.972 in.) 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm (0.010 in., 0.020 in., 0.030 in., 0.039 in.)

0.25 mm (0.010 in.) 0.50 mm (0.020 in.) 0.75 mm (0.030 in.) Flywheel

Out-of-roundness

Oil pump

Outer gear

Clearance between outer circumference

and front case

Clearance between addendum and crescent

(0.010 in., 0.020 in., 0.030 in., 0.039 in.)

0.05 mm (0.0020 in.) or less 0.10 mm (0.0039 in.) or less 0.10-0.25 mm (0.004-0.010 in.)

0.01-0.06 mm (0.0004-0.0024 in.) 0.25 mm, 0.50 mm, 0.75 mm (0.01 in., 0.02 in., 0.03 in.)

42 mm (1.6535 in.)

48 mm (1.8898 in.) Within 0.03 mm (0.0012 in.) Within 0.01 mm (0.0004 in.) 0.05-0.18 mm (0.002-0.007 in.)

41.735-41.750 mm (1.6431-1.6437 in.) 41.485-41.500 mm (1.6333-1.6339 in.) 41.235-41.250 mm (1.6234-1.6240 in.)

47.735-47.750 mm (1.8793-1.8799 in.) 47.485-47.500 mm (1.8695-1.8701 in.) 47.235-47.250 mm (1.8596-1.8602 in.)

Within 0.13 mm (0.005 in.)

0.1-0.2 mm (0.0039-0.0079 in.)

0.22-0.34 mm (0.0087-0.0134 in.) 0.04-0.10 mm (0.0016-0.0039 in.)

0.21-0.32 mm (0.0083-0.0126 in.) 0.04-0.10 mm (0.0016-0.0039 in.)

47 mm (1.850 in.) 4.3 kg/40 mm (9.5 lb/1.575 in.)

2 0 - 4

SERVICE STANDARD

Standard value

Belt deflection

Clearance between timing belt and seal line

Piston pin press in load

Front engine support bracket bolt

Front roll stopper bracket bolt

Rear roll stopper bracket bolt

Left engine support bracket bolt

Oil pressure switch

Cylinder Head

Cylinder head bolt-cold engine

-hot engine Intake/exhaust manifold bolt or nut

Rocker cover bolt

Rocker arm shaft bolt

Camshaft bolt

Rear plate bolt

Jet valve

Main Moving

Connecting rod cap nut

Crankshaft bearing cap

Fly wheel (manual transmission) bolt

Drive plate (automatic transmission) bolt

Timing Belt

Crankshaft pulley bolt

Crankshaft sprocket bolt

Camshaft sprocket bolt

Timing belt tensioner bolt

Timing belt cover bolt

Front case bolt

59-78 600-800 43-58 54-69 550-700 40-51 29-39 300-400 22-29 59-78 600-800 43-58 15-21 150-210 11-15

69-74 700-750 51-54 78-83 800-850 58-61 16-19 160-190 12-14 1.5-2.0 15-20 1.1-1.4 20-26 200-270 14-20 20-26 200-270 14-20 7.8-9.8 80-100 5.8-7.2 18-22 180-220 13-16

31-34 320-350 49-53 500-540 127-137 1,300-1,400 127-137 1,300-1,400

12-15 122-150 8.7-11 69-98 700-1,000 51-72 64-74 650-750 47-54 20-26 200-270 14-20 9.8-12 100-120 7.2-8.7 12-15 120-150 8.7-11

23-25 36-39 94-101 94-101

Nm kg.cm Ib.ft Engine Mounting

Left mounting insulator (large) nut 59-78 600-800 43-58

Left mounting insulator (small) nut 29-39 300-400 22-29

Left mounting bracket to engine nut 49-64 500-650 36-47

Transmission mount insulator bolt 59-78 600-800 43-58

Transmission insulator bracket to side member bolt 29-39 300-400 22-29

Transmission mount bracket to automatic transmission nut 59-78 600-800 43-58

Rear roll insulator bolt 29-39 300-400 22-29

Rear roll stopper bracket to crossmember bolt 29-39 300-400 22-29

Front roll rod upper bolt 29-39 300-400 22-29

Front roll rod lower bolt 54-69 550-700 40-51

Recommended SAE viscosity number

*1 Restricted by driving condition and dealing area.

*2 Not recommended for sustained high speed vehicle operation.

For best performance and for maximum protection of all engines for all types of operation, select only those lubricants which:

1 Conform to the requirements of API classification.

2 Have proper SAE grade number for expected ambient temperature range.

Lubricants which do not have both an SAE grade number and an API service classification on the container should not be used.

20-6

SELECTION OF THE COOLANT

Coolant

RELATION BETWEEN ANTIFREEZE CONCENTRATION AND SPECIFIC GRAVITY

The following table is applicable only to the specified HIGH QUALITY ETHYLENE GLYCOL (ANTIFREEZE) COOLANT.

Coolant temperature °C (°F) and specific gravity Freezing Safe operating Coolant

temperature temperature concentration

10 (50) 20 (68) 30 (86) 40 (104) 50 (122) °C (°F) °C (°F) (Specific volume) 1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%

Example

The safe operating temperature is - 15°C (5°F) when the measured specific gravity is 1.058 at the coolant ture of 20°C (68°F).

Mount bushing remover and

installer ring

Removal and installation of the front roll rod upper bushing (use with 09216-21000 and 09216-21100)

20-8

Cylinder head bolt wrench

Removal and tightening of the cylinder head bolt

09221-21000

Camshaft oil seal installer

Installation of the camshaft oil seal (use with 09221-21100)

09221-21100

Camshaft oil seal guide

Using as a guide when pressing in the camshaft oil seal (use with 09221-21000)

09222-21001

Valve spring compressor

Removal and installation of the inlet or exhaust valve

09222-21100

Valve stem oil seal installer

09222-21200

Valve guide installer

Installation of the valve stem oil seal

Removal and installation of the valve guide

20-10

Tool

(Number and name) Illustration Use

09391-21101

Harness connector for FBC

Inspection for FBC system (use with 21000)

TROUBLESHOOTING

Symptom

Misalignment of suspension

Vehicle will not move

Noise occurs when accelerating

or decelerating

Body vibration

Loose transmission mount

Probable cause Bent engine mount bracket Deformed engine roll stopper and roll bracket Broken insulator in engine roll stopper Deformed engine mount pipe

Deformed transmission mount bracket Broken engine front mount bracket Broken engine rear mount bracket Broken rod in engine mount bracket Broken transmission mount bracket Loose engine front mount bracket Loose engine rear mount bracket Loose engine roll stopper bracket Loose transmission mount bracket Broken engine mount insulator Broken transmission mount insulator Loose bolt tightening transmission mount bracket

Remedy Replace bracket Replace bracket Replace insulator Replace pipe Replace bracket Replace bracket Replace bracket Replace bracket or rod Replace bracket Retighten bolt Retighten bolt Retighten bolt Retighten bolt Replace insulator Replace insulator Reposition mounting parts

20-12

GENERAL

20-14

RETORQUING OF CYLINDER HEAD BOLTS

1 When cylinder head bolts are retorqued, first slightly loosen and then tighten to specified torque.

2 Be sure to follow the specific torquing sequence.

3 After cylinder head bolts have been tightened to specified torque, run engine until normal operating temperature is reached, allow it to cool down, and then retorque bolts to speci- fication for best results.

Tightening torque

Cold engine 69-73 Nm (704-745 kg.cm, 51-54 Ib.ft) Hot engine 79-83 Nm (806-847 kg.cm, 58-61 Ib.ft)

ENGINE OIL LEVEL GAUGE

1 The oil level gauge is located on the forward side of the engine.

2 Maintain engine oil level within the marking lines on the oil level gauge The oil level in the oil pan may read at the “MAX” mark line (upper limit) after the engine has been standing for several hours, but when the engine is started the oil level will drop somewhat due to filling of oil passage, etc.

3 When the oil level is at or below the “MIN” mark line (lower limit) on the level gauge, add 1 liter (1 U.S quart) The oil should never be allowed to remain below the lower limit.

as a replacement filter in service on all vehicles.

The quality of replacement filter varies considerably Only high quality filter should be used to assure most efficient service.

Replacing Oil Filter

1 Use filter wrench or the like to remove oil filter Clean the mounting surface on the block carefully.

2 Apply a thin film of engine oil to the surface of the new gasket before screwing filter on.

3 Then tighten filter enough by hand.

4 Start and run engine and check for engine oil leaks.

5 After stopping engine, check oil level and replenish as sary.

3 After installing flange, crankshaft sprocket and camshaft sprocket match timing mark of each sprocket as shown in illustration.

As a result of this, get piston in No 1 cylinder at top dead center

NOTE

Allow tensioner to remain in assemble state must be installed

temporarily as follows.

o Tentatively tighten tensioner at position as shown in

illus-tration, in state that one extended end of spring tensioner

is assembled to bend of tensioner bracket as imaginary

line (wheel spring tensioner is inoperative and not loaded).

o Then set extended end of tensioner spring at front case

with drive etc.

4 Install timing belt so as not to give slack to tension side Then

make sure all timing marks are at correct position respectively

with tension side in strained state by applying force to camshaft

sprocket in reversing (counterclockwise) direction.

1 Remove timing belt upper cover and water pump pulley.

2 Check the belt for cracking, peeling or other damage Be sure to carefully check the entire length of the belt.

3 Set the engine so that the No 1 cylinder is at the compression top dead center In other words, align the timing mark on the camshaft sprocket with that on the cylinder head.

Note that the crankshaft should be turned clockwise, not in reverse Turning the crankshaft counterclockwise will cause the tension to become improperly adjusted.

4 Remove the timing belt lower cover.

5 Loosen the tensioner mounting bolts 1 and 2 in that order as shown to give the timing belt only spring tension.

6 Check the belt to ensure that it is not out of position.

20-18

7 Tighten the tensioner attaching bolts 2 and 1 in that order as

shown If the bolt 1 is tightened first, the tensioner will move

with the bolt and cause the belt to become overtightened.

8 Give the crankshaft one turn in operating direction (clockwise)

and realign crankshaft sprocket timing mark with the top dead

center position.

CAUTION:

Do not turn the crankshaft in a reverse direction The

crank-shaft should be turned smoothly clockwise.

9 Loosen the tensioner attaching bolts 1 and 2 in that order as

shown.

10 Retighten the tensioner attaching bolts 2 and 1 in that order as

shown to the specified torque.

Tightening torque

20-26 Nm (200-270 kg.cm, 14-20 Ib.ft)

11 Then recheck the belt tension Verify that when the tensioner

and the tension side of the timing belt are pushed in

horizon-tally with a moderate force [approx 49 N (11 lb)], the timing

belt cog end is approx ½ of the tensioner mounting bolt head

radius (across flats) away from the bolt head center.

(counter-2 The measure bolt tension in the middle of tension side span Torque value of timing belt tension (In cool condition)

ENGINE MOUNTING

ENGINE MOUNTING

COMPONENTS

TORQUE : Nm (kg-cm Ib.ft)

ENGINE MOUNTING

REMOVAL

Attach a cable or chain to the engine hooks, and then lift enough

so that there is no pressure on the insulators.

Engine Mounting

1 Remove the engine mount insulator bolts.

2 Remove the engine mount bracket from the engine.

Transmission

1 For vehicles with a 5-speed manual transmission, remove the select control valve.

2 Remove the transmission mount bolt.

3 Detach the cap from the inside of the right fender shield, remove the transmission mounting bolts.

4 Remove the transmission bracket.

Front Roll Stopper

1 Remove the front roll stopper upper and lower bolts.

2 Remove the front roll rod assembly.

20-22

ENGINE MOUNTING Rear Roll Stopper

1 Remove the bolt from the rear roll stopper.

2 Remove the rear roll stopper from the No 2 crossmember.

ENGINE MOUNTING

NOTE

When the bushings are installed, observe the following dimensions.

Front roll stopper Rear roll stopper

NOTE

When installing the front roll stopper lower bolt, tighten the bolt

with its projection inserted into the slot.

ENGINE AND TRANSMISSION ASSEMBLY

ENGINE AND TRANSMISSION ASSEMBLY

REMOVAL

1 Remove the battery.

2 Detach the air cleaner.

3 Disconnect the connectors for the backup lamp and engine

harness.

4 For vehicle with a 5-speed 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.

7 For vehicles with an automatic transmission, disconnect the

transmission oil cooler hoses.

NOTE

When disconnecting the hoses, make identification marks

to avoid making any mistakes in reconnecting them.

CAUTION

Be careful not to spill any of the oil or fluid out of the hoses,

and the openings to prevent the entrance of foreign material.

8 Disconnect the radiator upper and lower hoses on the engine

side, and then remove the radiator assembly.

9 Disconnect the high tension cable and all wires to the

distribu-tor from the ignition coil section.

10 Disconnect the engine ground.

11 Disconnect the brake booster vacuum hose.

12 Remove the fuel main, return and vapor hoses from the engine

side.

13 Disconnect the heater hoses (inlet and outlet) on the engine

side.

14 Disconnect the accelerator cable at the engine side.

15 For vehicles with a manual transmission, remove the clutch

cable from the transmission.

16 For vehicles with an automatic transmission, remove the

con-trol cable from the transmission.

20-26

ENGINE AND TRANSMISSION ASSEMBLY

17 Disconnect the speedometer cable form the transmission.

18 Disconnect the air conditioner mounting bracket.

19 Jack up the vehicle.

20 Drain the transmission oil (or fluid).

21 Disconnect the front exhaust pipe from the manifold.

NOTE:

Use wire to suspend the exhaust pipe from the bottom of the

vehicle.

22 For vehicles with a manual transmission, remove the shift

control rod and extension rod.

23 Remove the lower arm ball joint bolts and the strut bar at the

point where it is mounted to the lower arm.

24 Remove the drive shafts from the transmission case.

CAUTION

(a) Plug up the holes of the transmission case to prevent

entry of foreign material.

(b) The circlips on the drive shafts should be replaced at

each removal.

25 Hang the lower arm and drive shaft from the body with a string.

26 Attach a cable to the engine, and use a chain block to lift the

engine only enough to pull cable tight.

27 Remove the front roll stopper.

28 Separate the rear roll stopper and the No 2 crossmember.

ENGINE AND TRANSMISSION ASSEMBLY

29 Remove the engine mounting insulator bolts.

30 Remove the engine mounting bracket from the engine.

31.

32.

33.

Slowly raise the chain block (to the extent that the engine and

transmission weights are not applied to the mounting

por-tions) and temporarily hold it in the raised condition.

CAUTION

Confirm that all of the cables, hoses, harnesses, connectors

etc., are disconnected from the engine.

Remove the blind cover from inside the right fender shield and

remove the transmission mount bracket bolts.

Remove the left mount insulator bolt.

While directing the transmission side downward, lift the

engine and transmission assembly up and out of the vehicles.

20-28

ENGINE AND TRANSMISSION ASSEMBLY

INSTALLATION

1 While checking the connections of the harnesses, pipes, hoses,

etc., and making sure that none of them are being caught,

damaged, etc., install the engine and transmission assembly.

2 When the engine and transmission assembly is installed to the

front roll stoppers, first tighten temporarily.

3 Then, after the weight of the engine and transmission assembly

has been put on each insulator, tighten to specified torque.

4 Reassemble all of the components removed during

disassem-bly Be especially careful to properly secure ail components,

including fuel, electrical and fluid pipe connections.

5 Replenish the coolant and check for leakage.

6 Replenish the transmission fluid, test the operation, and check

for leakage.

7 Check the operation of the transmission control cable and

accelerator cable, and adjust as necessary.

8 Check the operation of each of the various meters.

TIMING BELT TRAIN

TIMING BELT TRAIN

C O M P O N E N T

The timing belt train is driven by a cogged belt The timing belt drives the camshaft The timing belt is fully covered to keep out stones, water, sand and dust Do not drive the vehicle with the timing belt covers removed.

DISASSEMBLY

1 Remove the fan, spacer, water pump pulley and belt.

2 Remove the timing belt cover.

3 Move the timing belt tensioner fully toward the water pump and temporarily secure it.

4 Remove the timing belt from the camshaft sprocket.

5 Remove the camshaft sprocket.

6 Remove the crankshaft pulley.

7 Remove the timing belt If the timing belt is to reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before.

8 Remove the crankshaft sprocket bolts and remove the shaft sprocket and flange.

crank-9 Remove the timing belt tensioner.

20-30

TIMING BELT TRAIN

INSPECTION

Sprockets and Tensioner

1 Check the camshaft sprocket, crankshaft sprocket and

ten-sioner for abnormal wear, cracks damage and replace as

necessary.

2 Inspect tensioner for easy and smooth pulley rotation and check

for play or noise Replace as necessary.

Timing Belt

1 Check the belt for oil or dust deposits and replace if necessary.

The slight deposit should be wiped away with a dry cloth or

paper Do not clean with a solvent.

2 When the engine is overhauled or belt tension adjusted, check

the belt in detail If the following flaws are evident, replace the

belt with a new one.

Description Flaw conditions

1 Hardened back surface rubber Back surface glossy Non-elastic and so hard that even if a finger

nail is forced into it, no mark is produced.

2 Cracked back surface rubber

3 Cracked or separating canvas

TIMING BELT TRAIN

Description

4 Badly worn teeth (initial stage)

Flaw conditions Canvas on load side tooth flank worn (Fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture)

Flank worn (On load side)

5 Badly worn teeth (last stage) Canvas on load side tooth flank worn down and rubber exposed

(tooth width reduced)

6 Cracked tooth bottom

7 Missing tooth

8 Side of belt badly worn

9 Side of belt cracked

NOTE Normal belt should have precisely cut sides as if produced by a sharp knife.

20-32

TIMING BELT TRAIN

REASSEMBLY

1 Install the flange and crankshaft sprocket as shown, while

pay-ing heed to their mountpay-ing directions.

3 Align the timing marks of the camshaft sprocket and crankshaft

sprocket, with the piston in the No 1 cylinder placed at top dead

center on compression stroke.

TIMING BELT TRAIN

4 To install the timing belt tensioner, first mount the tensioner, spring and spacer and temporarily tighten the bolts Next, temporarily tighten the tensioner long hole side washer and bolts Install the bottom end of the spring in the position of the front case as shown in illustration.

5 Secure the tensioner to the position nearest the water pump.

6 Install the timing belt on the crankshaft sprocket

7 Install the timing belt on the camshaft sprocket.

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 cam- shaft sprocket in a reverse direction, all timing marks are in line.

8 install the crankshaft pulley In this case, make sure that the crankshaft sprocket pin fits the small hole in the pulley.

10 Tighten the tensioner tightening bolts 1 and 2 in that order If the bolt 1 is tightened first, the tensioner will move with the belt in the direction that the belt is tightened.

11 Give the crankshaft one turn in operating direction (clockwise) and realign crankshaft sprocket timing mark with the top dead center position.

2 0 - 3 4

TIMING BELT TRAIN

CAUTION

Do not turn the crankshaft in a reverse direction.

The crankshaft should be turned smoothly clockwise.

12 Loosen the tensioner attaching bolts 1 and 2 in that order.

13 Tighten the tensioner attaching bolts 2 and 1 in that order to

the specified torque.

Tightening torque

Tensioner attaching bolt

20-26 Nm (200-270 kg-cm, 14-20 Ib.ft)

14 Then recheck the belt tension Verify that when the tensioner

and the tension side of the timing belt are pushed in

horizon-tally with a moderate force [approx 49 N (11 lb)], the timing

belt cog end end is approx ½ of the tensioner mounting bolt

head radius (across flats) away from the bolt head center.

15 Install the timing belt cover.

16 Install the fan belt and adjust the belt tension.

ROCKER ARMS AND ROCKER SHAFT

ROCKER ARMS AND ROCKER SHAFT

COMPONENTS

Identification Installation position

1-3 No 1 and 3 cylinders (positions A and C in

illustration shown below) 2-4 No 2 and 4 cylinders (position B and D in

illustration shown below)

REMOVAL.

1 Remove the breather hose between the air cleaner and the

rocker cover.

2 Remove the air cleaner.

3 Remove the timing belt cover.

4 Remove the rocker cover.

5 Loosen the rocker shafts mounting bolts and remove the rocker

shafts, rocker arms and rocker shafts springs as an assembly.

6 Remove the bolts, the rocker arms and rocker shafts springs

from the rocker shafts.

INSPECTION

1 Check the rocker arm face that contacts the cam lobe and the

adjusting screw end that contacts the valve stem If badly worn

or damaged, replace rocker arm and/or adjusting screw(s).

2 Check the rocker arm shafts for damage Replace as necessary.

20-36