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2.4L 4-CYLINDER Engine: Specifications Hyundai Sonata IV

Mechanical

Crankcase Capacity

Oil capacity is 4.2 qts. (4.0L) with filter.

TORQUE SPECIFICATIONS

WARNINGFor updated reuse guidelines and tightening procedures of cylinder head, connecting rod and main bearing bolts, refer to TSB 02-20-002 CYLINDER HEAD/CONNECTING ROD/MAIN BEARING BOLT REUSE GUIDELINES & TORQUE SPECS .
ApplicationFt. Lbs. (N.m)
Auto Tensioner Bolt14-20 (19-27)
Block Plug Cap14-20 (19-27)
Camshaft Bearing Cap Bolt14-15 (19-20)
Camshaft Position Sensor Bolt11-16 (15-22)
Camshaft Sprocket Bolt58-72 (78-98)
Connecting Rod Cap Bolt
Step 115 (20)
Step 2Turn Additional 90 Degrees
Crankshaft Pulley Bolt80-94 (108-127)
Cylinder Head Bolts (1)
New Bolts
Step 147 (64) Then Release
Step 215 (20)
Step 3Turn Additional 90 Degrees
Step 4Turn Additional 90 Degrees
Original Bolts
Step 115 (20)
Step 2Turn Additional 90 Degrees
Step 3Turn Additional 90 Degrees
Engine Mounts
Bracket Bolt/Nut43-58 (58-79)
Front Roll Stopper
Bracket-To-Sub-Frame Bolt43-58 (58-79)
Bracket-To-Transaxle Bolt43-58 (58-79)
Insulator Bolt/Nut36-47 (49-64)
Insulator Bolt65-80 (88-108)
Rear Roll Stopper
Bracket-To-Sub-Frame Bolt36-47 (49-64)
Bracket-To-Transaxle Bolt43-58 (58-79)
Insulator Bolt/Nut36-47 (49-64)
Transaxle Mount
Bracket Bolt43-58 (58-79)
Insulator Bolt65-80 (88-108)
Sub-Bracket Bolt43-58 (58-79)
Exhaust Pipe Clamp Bolt14-22 (19-30)
Exhaust Pipe-To-Manifold Nut22-29 (30-39)
Flywheel-To-Crankshaft Bolt94-101 (127-137)
Front Case Bolt14-20 (19-27)
Front Case Plug Cap14-20 (19-27)
Idler Pulley Bolt33-40 (45-54)
Intake Manifold
Bracket Bolt13-18 (15-24)
Mounting Bolt
M8 Bolt11-14 (15-29)
M10 Bolt13-18 (18-24)
Mounting Nut22-30 (30-41)
Main Bearing Cap Bolt
Step 118 (25)
Step 2Additional 90 Degrees
Oil Drain Plug25-33 (34-45)
Oil Pump
Case Bolt14-20 (19-27)
Cover Bolt11-13 (15-18)
Driven Gear Bolt25-29 (34-39)
Sprocket Nut36-43 (49-58)
Oil Screen Bolt11-16 (15-22)
Starter Bolt20-25 (27-34)
Tensioner Pulley Bolt31-40 (42-54)
Tensioner Pulley Bracket Bolt17-20 (23-27)
Thermostat Housing Bolt/Nut11-15 (15-20)
Throttle Body-To-Intake Manifold Bolt11-15 (15-20)
Timing Belt
Lower & Upper Cover Bolt(2)
Rear Left Cover Bolt
Lower22-30 (30-41)
Upper(3)
Right Rear Cover Bolt(3)
Timing Belt Idler Bolt32-40 (43-55)
Timing Belt Tensioner Bolt32-40 (43-55)
Torque Converter-To-Drive Plate Bolt33-38 (45-53)
Water Pump Mounting Bolt11-15 (15-20)
INCH Lbs. (N.m)
Oil Pan Bolt89-106 (10-12)
Oil Pressure Switch71- 106 (8-12)
Oil Seal Case Bolt89-106 (10-12)
Rear Oil Seal Case Bolt89-106 (10-12)
Rocker Cover Bolt71-89 (8-10)
Valve Cover Bolts71-89 (8-10)
Water Pump Pulley Bolt71-89 (8-10)
(1) Tighten in sequence with engine cold. (Схема №5) (2) Tighten to 71-89 INCH lbs. (8-10 N.m). (3) Tighten to 89-106 INCH lbs. (10-12 N.m)
(1)Tighten in sequence with engine cold. (Схема №5)
(2)Tighten to 71-89 INCH lbs. (8-10 N.m).
(3)Tighten to 89-106 INCH lbs. (10-12 N.m)

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

ApplicationSpecification
Displacement143.5 Cu. In. (2.4L)
Bore3.41" (86.6 mm)
Stroke3.94" (100 mm)
Compression Ratio10:1
Fuel SystemMFI

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft
End Play.0098 (.250)
Main Bearings
Journal Diameter2.2434-2.2442 (56.982-57.002)
Journal Out-Of-Round.0006 (.015)
Journal Taper.0002 (.005)
Oil Clearance
No. 1, 2, 4 & 5.007-.0014 (.018-.036)
No. 3.0009-.0016 (.023-.041)
Connecting Rod Bearings
Journal Diameter1.7709-1.7717 (44.981-45.001)
Journal Out-Of-Round.0006 (.015)
Journal Taper.0002 (.005)
Oil Clearance.0008-.0020 (.020-.051)

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

ApplicationIn. (mm)
Maximum Bend.002 (.051)
Maximum Twist.004 (.10)
Side Play
Standard.004-.010 (.10-.025)
Service Limit.016 (.41)

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

ApplicationIn. (mm)
Pistons
Clearance.0008-.0012 (.20-.030)
Diameter (2)3.34153-3.3465 (84.97-85.001)
Rings
No. 1
End Gap.0098-.0138 (.250-.351)
Side Clearance.0008-.0024 (.020-.060)
No. 2
End Gap.0157-.0216 (.399-.549)
Side Clearance.0008-.0024 (.020-.060)
No. 3 (Oil)
End Gap.0039-.0157 (.099-.399)
Side ClearanceN/A
(1) Pin specifications are not available from manufacturer. (2) Diameter is measured at 90-degree angle to piston pin. See CYLINDER BL0CK ASSEMBLY under OVERHAUL.
(1)Pin specifications are not available from manufacturer.
(2)Diameter is measured at 90-degree angle to piston pin. See CYLINDER BL0CK ASSEMBLY under OVERHAUL.

PISTONS, PINS (1) & RINGS

CYLINDER BLOCK SPECIFICATIONS

ApplicationIn. (mm)
Cylinder Bore
Standard Diameter3.3453-3.3465 (84.971-85.001)
Maximum Taper.0004 (.010)
Maximum Out-Of-Round.0004 ( .010)
Deck Warpage (1)
Allowable Limit.002 (.051)
Service Limit.004 (.10)
(1) If deck warpage exceeds specification, machine deck surface. DO NOT remove more than a combined total of .008" (.20 mm) material from original surfaces of cylinder head and cylinder block
(1)If deck warpage exceeds specification, machine deck surface. DO NOT remove more than a combined total of .008" (.20 mm) material from original surfaces of cylinder head and cylinder block

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

ApplicationSpecification
Intake Valves
Length4.311" (109.5 mm)
Stem Diameter.2585-.2591" (6.566-6.581 mm)
Valve Head Thickness (Margin)
Standard Margin.040" (1.02 mm)
Minimum Margin Limit.028" (.71 mm)
Exhaust Valves
Length4.319" (109.70 mm)
Stem Diameter.2571-.2579" (6.530-6.551)
Valve Head Thickness (Margin)
Standard Margin.059" ( 1.5 mm)
Minimum Margin Limit.039" (.99 mm)
Valve Springs
Free Length1.804" (45.82 mm)
Out-Of-Square1.5°
Pressure @ Installed Height (1)55 lb. (248 N)
(1) Installed height information not available.
(1)Installed height information not available.

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

ApplicationSpecification
Maximum Warpage
Gasket Surface.0012" (.03 mm)
Manifold Surface.0059" (.150 mm)
Valve Seats
Seat Angle44-44.5°
Seat Width.035-.051" (0.89-1.30 mm)
Valve Guides
Intake Valve
Length1.791" (45.49 mm)
Valve Stem Guide-To-Guide Oil Clearance
Standard.0008-.0019" (.020-.048 mm)
Service Limit.004" (.10 mm)
Exhaust Valve
Length1.988" (50.5 mm)
Valve Stem Guide-To-Oil Clearance
Standard.0020-.0033" (.051-.084 mm)
Service Limit.0059" (.150 mm)

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

ApplicationIn. (mm)
End Play.0004-.0008 (.010-.020)
Journal Diameter1.102 (27.99)
Lobe Height
Intake
Standard1.3974 (35.494)
Service Limit1.3777 (34.994)
Exhaust
Standard1.3859 (35.202)
Service Limit1.3662 (34.701)
Oil Clearance.0020-.0029 (.051-.074)

CAMSHAFT

COUNTERBALANCE SHAFT SPECIFICATIONS

ApplicationIn. (mm)
Right Counterbalance Shaft
Front Journal Diameter1.6519-1.6526 (41.958-41.976)
Rear Journal Diameter1.6122-1.6129 (40.950-40.968)
Oil Clearance
Front.0008-.0024 (.020-.006)
Rear.0020-.0036 (.051-.091)
Left Counterbalance Shaft
Front Journal Diameter.7270-.7276 (18.466-18.481)
Rear Journal Diameter1.6126-1.6132 (40.960-40.975)
Oil Clearance
Front.0008-.0021 (.020-.0053)
Rear.0017-.0033 (.043-.084)

COUNTERBALANCE SHAFT

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