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Engine and Transaxle Assembly Removal & Installation - Hev

Engine and Transaxle Assembly Removal & Installation - 2.4L - Except Hev

Engine and Transaxle Assembly Removal & Installation - 2.0L - Except Hev

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General Information (Engine Mechanical System) - 2.0L - Except Hev: Specifications Hyundai Sonata VI

Mechanical

SPECIFICATIONS

Description		Specifications	Limit
General
Type		In-line, DOHC
Number of cylinders		4
Bore		86mm (3.385in.)
Stroke		86mm (3.385in.)
Total displacement		1998cc (121.92cu.in)
Compression ratio		9.5 ± 0.3 : 1
Firing order		1-3-4-2
Valve timing
Intake valve	Opens	ATDC 7° ~ BTDC 38°
Intake valve	Closes	ABDC 67° ~ ABDC22°
Exhaust valve	Opens	BBDC 54° ~ BBDC 9°
Exhaust valve	Closes	BTDC 10° ~ ATDC35°
Valve clearance [Engine coolant temperature : 20°C (68°F)]
Intake valve		0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)	0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust valve		0.32 ~ 0.38mm (0.0126 ~ 0.0150 in.)	0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
Camshaft
Cam height	Intake	44.2mm (1.7401in.)
Cam height	Exhaust	45.0mm (1.7716in.)
Journal outer diameter	Intake	No. 1 : []30mm (1.1811in.) No. 2,3,4,5 : []24mm (0.9449in.)
Journal outer diameter	Exhaust	No. 1 : []36mm (1.4173in.) No. 2,3,4,5 : []24mm (0.9449in.)
Bearing oil clearance	Intake	No. 1 : 0.022 ~ 0.057mm (0.00087 ~ 0.00224in.) No. 2,3,4,5 : 0.030~0.067mm (0.00118 ~ 0.00264 in.)	No. 1 : 0.090mm (0.00354in.) No. 2,3,4,5 : 0.120mm (0.00472in.)
Bearing oil clearance	Exhaust	No. 1 : 0 ~ 0.032mm (0 ~ 0.00126in.) No. 2,3,4,5 : 0.030~0.067mm (0.00118 ~ 0.00264 in.)
End play		0.04 ~ 0.16mm (0.0016 ~ 0.0063in.)	0.20mm (0.0078in.)
Valve
Valve length	Intake	113.18mm (4.4559in.)	112.93mm (4.4461in)
Valve length	Exhaust	105.79mm (4.1650in.)	105.59mm (4.1571in)
Stem outer diameter	Intake	5.465 ~ 5.480mm (0.21516 ~ 0.21575in.)
Stem outer diameter	Exhaust	5.458 ~ 5.470mm (0.21488 ~ 0.21535in.)
Face angle		45.25° ~ 45.75°
Thickness of valve head (margin)	Intake	1.02mm (0.0401in.)
Thickness of valve head (margin)	Exhaust	1.09mm (0.0429in.)
Valve stem to valve guide clearance	Intake	0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)	0.070mm (0.00275in.)
Valve stem to valve guide clearance	Exhaust	0.030 ~ 0.054mm (0.00118 ~ 0.00212in.)	0.090mm (0.00354in.)
MLA outer diameter		31.964 ~ 31.980mm (1.2584 ~ 1.2590in.)
Tappet bore inner diameter		32.000 ~ 32.025mm (1.2598 ~ 1.2608in.)
MLA to tappet bore clearance		0.020 ~ 0.061mm (0.00078 ~ 0.00240in.)	0.070mm (0.00275in.)
Valve guide
Length	Intake	43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)
Length	Exhaust	43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)
Inner diameter	Intake	5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)
Inner diameter	Exhaust	5.500 ~ 5.512mm (0.21654 ~ 0.21701in.)
Valve seat
Width of seat contact	Intake	1.16 ~ 1.46mm (0.0457 ~ 0.0575in.)
Width of seat contact	Exhaust	1.35 ~ 1.65mm (0.0531 ~ 0.0649in.)
Seat angle	Intake	44.75° ~ 45.10°
Seat angle	Exhaust	44.75° ~ 45.10°
Valve spring
Free length		47.44mm (1.8677in.)
Load		19.0 ± 0.6kg/35.0mm (41.88 ± 1.32lb/1.3779in 39.8 ± 1.2kg/26.0mm (87.74 ± 2.64lb/1.0236in.)
Out of squareness		Less than 1.5°
Cylinder head
Flatness of gasket surface		Less than 0.05mm (0.0019in.) for total area Less than 0.02mm (0.0007in.) for a section of 100mm (3.9370in.) x100mm (3.9370in.)
Flatness of manifold mounting surface	Intake	Less than 0.10mm (0.0039in.)
Flatness of manifold mounting surface	Exhaust	Less than 0.10mm (0.0039in.)
Piston
Piston outer diameter		85.970 ~ 86.000mm (3.3846 ~ 3.3858 in)
Piston to cylinder clearance		0.020 ~ 0.040mm (0.00079 ~ 0.00157in.)
Ring groove width	No. 1 ring	1.235 ~ 1.250mm (0.04862 ~ 0.04921in.)	1.260mm (0.04961in.)
	No. 2 ring	1.530 ~ 1.550mm (0.06023 ~ 0.06102 in)	1.560mm (0.06141in)
	Oil ring	2.010 ~ 2.025mm (0.07913 ~ 0.07972in.)	2.050mm (0.08071in.)
Piston ring
Side clearance	No. 1 ring	0.050 ~ 0.080mm (0.00197 ~ 0.00315in.)	0.100mm (0.00394in.)
	No. 2 ring	0.040 ~ 0.080mm (0.00157 ~ 0.00315in.)	0.100mm (0.00394in.)
	Oil ring	0.020 ~ 0.055mm (0.00079 ~ 0.00217in.)	0.100mm (0.00394in.)
End gap	No. 1 ring	0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)	0.60mm (0.0236in.)
	No. 2 ring	0.30 ~ 0.45mm (0.0118 ~ 0.0177 in)	0.70mm (0.0275in.)
	Oil ring	0.20 ~ 0.50mm (0.0079 ~ 0.0197in.)	0.80mm (0.0315in.)
Piston pin
Piston pin outer diameter		21.997 ~ 22.000mm (0.86602 ~ 0.86614in.)
Piston pin hole inner diameter		22.003 ~ 22.007mm (0.86626 ~ 0.86642in.)
Piston pin hole clearance		0.003 ~ 0.010mm (0.00012 ~ 0.00039in.)
Connecting rod small end hole inner diameter		22.005 ~ 22.011mm (0.86634 ~ 0.86657in.)
Piston pin-to-connecting rod interference		0.005 ~ 0.014mm (0.00020 ~ 0.00055in.)
Connecting rod
Connecting rod big end inner diameter		51.000 ~ 51.018mm (2.00787 ~ 2.00858in.)
Connecting rod bearing oil clearance		0.031 ~ 0.045mm (0.00122 ~ 0.00177in.)	0.050mm (0.00197in.)
Side clearance		0.10 ~ 0.25mm (0.0039 ~ 0.0098in.)	0.35mm (0.0138in.)
Crankshaft
Main journal outer diameter		51.942 ~ 51.960mm (2.04496 ~ 2.04567in.)
Pin journal outer diameter		47.954 ~ 47.972mm (1.88795 ~ 1.88866in.)
Main bearing oil clearance		0.020 ~ 0.038mm (0.00079 ~ 0.00150in.)	0.100mm (0.00394in.)
End play		0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)	0.30mm (0.0118in.)
Cylinder block
Cylinder bore		86.00 ~ 86.03mm (3.3858 ~ 3.3870in.)
Flatness of gasket surface		Less than 0.05mm (0.0019in.) for total area Less than 0.02mm (0.0007in.) for a section of 100mm (3.9370in.) x100mm (3.9370in.)
Engine oil
Oil quantity	Total	5.5 L (1.45 U.S.gal., 5.81 U.S.qt., 4.84 lmp.qt.)	When replacing a short engine or block assembly
	Oil pan	4.2 L (1.11 U.S.gal., 4.44 U.S.qt., 3.70 lmp.qt.)
	Drain and refill	4.6 L (1.22 U.S.gal., 4.86 U.S.qt., 4.05 lmp.qt.)	Including oil filter
Oil grade	Recommendation	5W-30 ACEA A5	If not available, refer to the recommended API or ILSAC or ACEA classification and SAE viscosity number.
	Classification	API SL, SM or above ILSAC GF3, GF4 or above ACEA A3 or A5	Satisfy the requirement of the API or ILSAC or ACEA classification
	SAE viscosity grade	Recommended SAE viscosity number	Refer to the " LUBRICATION SYSTEM ".
Oil pressure (at 1,000rpm)		117.68kPa (1.2kgf/cm 2 , 17.07psi) or above	Oil temperature (oil pan): 110±2°C (230±35.6°F)
Cooling system
Cooling method		Forced circulation with cooling fan
Coolant quantity		6.5 ~ 6.6L (1.72 ~ 1.74 U.S.gal., 6.87 ~ 6.97 U.S.qt., 5.72 ~ 5.81 lmp.qt.)
Thermostat	Type	Wax pellet type
	Opening temperature	82±1.5°C (179.6±2.7°F)
	Full opening valve lift/temperature	More than 8mm (0.3in.)/95°C (203°F)
Radiator cap	Main valve opening pressure	93.16 ~ 122.58kPa (0.95 ~ 1.25kgf/cm 2 , 13.51 ~ 17.78psi)
Radiator cap	Vacuum valve opening pressure	0 ~ 6.86 kPa (0 ~ 0.07kgf/cm 2 , 0 ~ 0.99psi)

GENERAL SPECIFICATION CHART

TIGHTENING TORQUES

Item	Quantity	N.m	Kgf.m	Lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt	4	58.8 ~ 73.5	6.0 ~ 7.5	43.4 ~ 54.2
Engine mounting insulator to engine mounting support bracket fixing nut	1	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Engine mounting support bracket to engine support bracket fixing bolt	1	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Engine mounting support bracket to engine support bracket fixing nut	2	78.5 ~ 98.1	8.0 ~ 10.0	57.9 ~ 72.3
Transaxle mounting bracket to body fixing bolt	3	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting bracket to body fixing nut	1	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Transaxle mounting support bracket fixing bolt	4	58.8 ~ 78.5	6.0 ~ 8.0	43.4 ~ 57.9
Transaxle mounting bracket to transaxle mounting support bracket fixing bolt	2	88.3 ~ 107.9	9.0 ~ 11.0	65.1 ~ 79.6
Roll rod bracket to sub frame fixing bolt	2	49.0 ~ 63.7	5.0 ~ 6.5	36.2 ~ 47.0
Roll rod bracket to roll rod support bracket fixing bolt & nut	1	88.3 ~ 107.9	9.0 ~ 11.0	65.1 ~ 79.6
Timing system
Idler bolt	2	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Drive belt tensioner pulley bolt	1	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Drive belt tensioner bolt	1	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
Crankshaft pulley bolt	1	166.6 ~ 176.4	17.0 ~ 18.0	122.9 ~ 130.1
Timing chain cover service hole bolt	1	11.8 ~ 14.7	1.2 ~ 1.5	8.7 ~ 10.8
Timing chain cover bolt (M6x25)	7	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Timing chain cover bolt (M8x28)	7	18.6 ~ 22.5	1.9 ~ 2.3	13.7 ~ 16.6
Engine support bracket bolt (M8x30)	1	19.6 ~ 24.5	2.0 ~ 2.5	14.5 ~ 18.1
Engine support bracket bolt (M10x40)	1	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Engine support bracket bolt (M10x45)	2	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Timing chain tensioner bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain tensioner arm bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain guide bolt	3	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Timing chain oil jet bolt	1	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Cylinder head
Engine cover mounting bolt	4	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Ignition coil bolt	4	3.9 ~ 5.9	0.4 ~ 0.6	2.9 ~ 4.3
Cylinder head cover bolt	20	[3.9~5.9] + [7.8~9.8]	[0.4~0.6] + [0.8~1.0]	[2.9~4.3] + [5.8~7.2]
High pressure fuel pipe nut	2	26.5 ~ 32.4	2.7 ~ 3.3	19.5 ~ 23.9
High pressure fuel pump bolt	2	12.7 ~ 14.7	1.3 ~ 1.5	9.4 ~ 10.8
High pressure fuel pump bracket bolt	3	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
CVVT bolt (LH/RH)	2	53.9 ~ 63.7	5.5 ~ 6.5	39.7 ~ 47.0
OTS (Oil temperature sensor)	1	19.6 ~ 39.2	2.0 ~ 4.0	14.5 ~ 28.9
Camshaft bearing cap bolt (M6) (LH/RH)	16	[5.9] + [10.8~12.7]	[0.6] + [1.1~1.3]	[4.3] + [8.0~9.4]
Camshaft bearing cap bolt (M8)	4	[14.7] + [27.5 ~ 31.4]	[1.5] + [2.8~3.2]	[10.8] + [20.3~23.1]
Cylinder head bolt	10	[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)	2	27.5 ~ 31.4	2.8 ~ 3.2	20.3 ~ 23.1
Camshaft position sensor (LH/RH)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil control valve (OCV) bolt (LH/RH)	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Cylinder block
Tensioner assembly integrated bracket bolt	5	39.2 ~ 44.1	4.0 ~ 4.5	28.9 ~ 32.5
Flywheel bolt	7	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 93.9
Drive plate bolt	7	117.7 ~ 127.5	12.0 ~ 13.0	86.8 ~ 93.9
Oil filter bracket bolt	4	21.6 ~ 26.5	2.2 ~ 2.7	15.9 ~ 19.5
Ladder frame bolt	10	[8.8~9.8] + [17.7~20.6] + [27.5~31.4]	[0.9~0.1] + [1.8~2.1] + [2.8~3.2]	[6.5~7.2] + [13.0~15.2] + [20.3~23.1]
Connecting rod bearing cap bolt	8	[17.7~21.6] + [88~92°]	[1.8~2.2] + [88~92°]	[13.0~15.9] + [88~92°]
Main bearing cap bolt	10	[14.7] + [27.5~31.4] + [120~125°]	[1.5] + [2.8~3.2] + [120~125°]	[10.8] + [20.3~23.1] + [120~125°]
Piston cooling oil jet bolt	4	24.5 ~ 29.4	2.5 ~ 3.0	18.1 ~ 21.7
Crankshaft position sensor	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Crankshaft position sensor cover bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Knock sensor	1	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Lubrication system
Oil drain plug	1	34.3 ~ 44.1	3.5 ~ 4.5	25.3 ~ 32.5
Oil filter	1	11.8 ~ 15.7	1.2 ~ 1.6	8.7 ~ 11.6
Oil level gauge assembly bolt	1	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
A/C compressor bracket bolt	4	19.6 ~ 23.5	2.0 ~ 2.4	14.5 ~ 17.4
Oil pan bolt (M6)	16	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Oil pan bolt (M9)	2	30.4 ~ 34.3	3.1 ~ 3.5	22.4 ~ 25.3
BSM chain tensioner arm bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
BSM chain guide bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
BSM chain tensioner bolt	2	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Balance shaft module (BSM) bolt (M9x181.5)	4	[22.6~26.5]+[88~92°]	[2.3~2.7]+[88~92°]	[16.6~19.5]+[88~92°]
Balance shaft module (BSM) bolt (M9x95)	2	[22.6~26.5]+[43~47°]	[2.3~2.7]+[43~47°]	[16.6~19.5]+[43~47°]
Oil pressure switch	1	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Cooling system
Water pump pulley bolt	3	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Water pump cover bolt	5	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Water pump sub assembly bolt	5	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Water inlet fitting bolt	3	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Water temperature control assembly nut	1	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Water temperature control assembly bolt	2	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Water inlet pipe bolt	1	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Intake and exhaust system
Air intake hose clamp bolt	1	2.9 ~ 4.9	0.3 ~ 0.5	2.2 ~ 3.6
Air cleaner assembly bolt	2	7.8 ~ 9.8	0.8 ~ 1.0	5.8 ~ 7.2
Electronic throttle control (ETC) module bolt	4	9.8 ~ 11.8	1.0 ~ 1.2	7.2 ~ 8.7
Intake manifold stay bolt	4	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Intake manifold bolt	3	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Intake manifold nut	2	18.6 ~ 23.5	1.9 ~ 2.4	13.7 ~ 17.4
Oxygen sensor (Front/Rear)	2	39.2 ~49.0	4.0 ~ 5.0	28.9 ~ 36.2
Turbocharger oil drain pipe assembly bolt	2	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 7.2
Turbocharger oil drain pipe assembly nut	2	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 7.2
Turbocharger water hose bolt	2	26.5 ~ 32.4	2.7 ~ 3.3	19.5 ~ 23.9
Turbocharger oil feed pipe & hose bolt	2	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Turbocharger oil feed pipe & hose eye bolt	1	11.8 ~ 17.7	1.2 ~ 1.8	8.7 ~ 13.0
Turbo manifold module heat protector bolt	6	7.8 ~ 11.8	0.8 ~ 1.2	5.8 ~ 8.7
Turbo manifold module stay bolt (M8)	2	18.6 ~ 27.5	1.9 ~ 2.8	13.7 ~ 20.3
Turbo manifold module stay bolt (M10)	2	49.0 ~ 53.9	5.0 ~ 5.5	36.2 ~ 39.7
Turbo manifold module nut	9	49.0 ~ 53.9	5.0 ~ 5.5	36.2 ~ 39.7
Turbo adapter nut	6	49.0 ~ 53.9	5.0 ~ 5.5	36.2 ~ 39.7
Catalytic converter/muffler nut	8	39.2 ~ 58.8	4.0 ~ 6.0	28.9 ~ 43.4
Intercooler inlet pipe mounting bolt	1	14.7 ~ 19.6	1.5 ~ 2.0	10.8 ~ 14.5
Intercooler hose clamp bolt	3	4.9 ~ 6.9	0.5 ~ 0.7	3.6 ~ 5.1
Intercooler mounting bracket bolt	2	3.9 ~ 5.9	0.4 ~ 0.6	2.9 ~ 4.3

TIGHTENING TORQUES SPECIFICATION CHART