Help
After searching for weeks I have finally found a complete service manual to suit 1998 - 2000 Hyundai Tiburon.
It has diagrams, exploded views, parts list, assembly instructions, wiring diagrams, the works. Obviously I am not going to post the complete manual, but I can provide sections upon request - FREE.
Here is a sample of what I found:
SERVICE MANUAL
Hyundai Coupe/Tiburon 1998-2000
Engine Mechanical System General:
SPECIFICATIONS
General
Description
Specification 1.8L
Specification 2.0L
Type
In-line, Double Over Head Camshaft
In-line, Double Over Head Camshaft
Number of cylinders
4 - 1.8L Eng. [G4GM]
4 - 2.0L Eng. [G4GF]
Bore
82 mm (3.228 in.)
82 mm (3.228 in.)
Stroke
85 mm (3.346 in.)
93.5 mm (3.681 in.)
Total displacement
1795 CC
(109.54 cu.in.)
1975 CC
(120.52 cu.in.)
Compression ratio
10.0
10.3
Firing order
1-3-4-2
1-3-4-2
Idle R.P.M
800±100
800±100
Ignition timing at idling speed
BTDC 10°±5°/
800 rpm
BTDC 10°±5°/
800 rpm
Cylinder block
Description
Specification
Cylinder bore
82.00-82.03 mm
(3.2283-3.2295 in.)
[1.8L, 2.0L]
Out-of-roundness and taper of cylinder bore
Less than 0.01 mm
(0.0004 in.)
Clearance with piston
0.02-0.04 mm
(0.0008- 0.0016 in.)
Piston
Description
Specification
O.D.
81.97-82.00 mm
(3.2271-3.2283 in.) [1.8L, 2.0L]
Service size
0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize
Piston ring
Description
Specification
Limit
Side clearance
No. 1
0.04-0.08 mm
(0.0015-0.0031 in.)
0.1 mm
(0.004 in.)
No. 2
0.03-0.07 mm
(0.0012-0.0027 in.)
End gap 1.8L
No. 1
0.23-0.38 mm
(0.0090-0.0149 in.)
1 mm
(0.0394 in.)
No. 2
0.45-0.60 mm
(0.0177-0.0236 in.)
1 mm
(0.0394 in.)
Oil ring side rail
0.20-0.60 mm
(0.0078-0.0236 in.)
1 mm
(0.0394 in.)
End gap 2.0L
No. 1
0.23-0.38 mm
(0.0090-0.0149 in.)
1 mm
(0.039 in.)
No. 2
0.33-0.48 mm
(0.0130-0.0189 in.)
1 mm
(0.039 in.)
Oil ring side rail
0.20-0.60 mm
(0.0078-0.0236 in.)
1 mm
(0.039 in.)
Service size
|
0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize
|
Connecting rod
Description
Specification
Limit
Bend
0.05 mm (0.0020 in.) or less
|
Twist
0.1 mm (0.004 in.) or less
|
Connecting rod big end to crankshaft side clearance
0.100-0.250 mm
(0.0039-0.0098 in.)
0.4 mm (0.0157 in.)
Connecting rod bearing
Description
Specification
Oil clearance
0.2024-0.044 mm
(0.0009-0.0017 in.)
Undersize
0.25, 0.50, 0.75 mm
(0.01, 0.02, 0.03 in.)
Camshaft
Description
Dimensions
Specification
Limit
Cam height (Intake 1.8L)
|
44.449 mm (1.7499 in.)
44.349 mm
(1.7460 in.)
Cam height (Intake 2.0L)
|
44.049 mm (1.7342 in.)
43.949 mm
(1.7302 in.)
Cam height (Exhaust)
|
45.049 mm (1.7736 in.)
44.949 mm
(1.7696 in.)
Journal O.D.
|
28 mm
(1.1023 in.)
|
Bearing oil clearance
|
0-0.025 mm
(0-0.0009 in.)
|
End play
|
0.01-0.2 mm
(0.004-
0.008 in.)
|
Pin O.D.
|
45 mm
(1.77 in.)
|
Journal O.D.
|
57 mm
(2.244 in.)
|
Bend
|
0.03 mm (0.0012 in.) or less
|
Out-of-roundness, taper of journal and pin
|
0.01 mm (0.0004 in.) or less
|
End play
|
0.06-0.260 mm
(0.0023-
0.010 in.)
0.30 mm (0.0118 in.)
Undersize rework dimension of pin
0.25 mm
(0.010 in.)
44.725-
44.740 mm
(1.7608-
1.7614 in.)
|
0.50 mm
(0.020 in.)
44.475-
44.490 mm
(1.7509-
1.7516 in.)
|
0.75 mm
(0.030 in.)
44.225-
44.240 mm
(1.7411-
1.7417 in.)
|
Undersize rework dimension of journal
0.25 mm
(0.010 in.)
56.727-
56.742 mm
(2.2333-
2.2339 in.)
|
Crankshaft
Description
Dimensions
Specification
Undersize rework dimension of journal
0.50 mm
(0.020 in.)
56.477-56.492 mm
(2.2235-
2.2240 in.)
0.75 mm
(0.030 in.)
56.227-56.242 mm
(2.2136-
2.2142 in.)
Flywheel
Description
Specification
Limit
Runout
0.1 mm
(0.0039 in.)
0.13 mm
(0.0051 in.)
Cooling method: Water-cooled, Pressurized, Forced circulation with electrical fan
Coolant
Description
Specification
Quantity
6 lit (6.3 U.S qts.,
5.2 Imp. qts.)
Radiator
Description
Specification
Type
Pressurized corrugated fin type
Performance
43250 Kcal/h
Radiator cap
Description
Specification
Main valve opening pressure
81.4-110 kpa (11.8-15.6 psi., 0.83-1.1kg/cm2)
Vacuum valve opening pressure
-6.86 kpa (-1.00 psi, -0.07 kg/cm2) or less
Coolant pump (Centrifugal type impeller)
Description
Specification
Type
Wax pellet type with jiggle valve
Valve opening temperature
82°C (177°F)
Full-opening temperature
95°C (201°F)
Drive belt
Description
Specification
Type
V-ribbed belt
Engine coolant temperature sender
Description
Specification
Type
Thermistor
Resistance
90.5-117.5 OHM at 70°C (158°F) 21.3-26.3 OHM at 115°C (239°F)
Engine coolant temperature sensor
Description
Specification
Type
Heat-sensitive thermistor
Resistance
2.27-2.73 KOHM at 20°C (68°F) 290-354 OHM at 80°C (176°F)
Automatic transaxle oil cooler
Description
Specification
Performance
1,200 Kcal/h
Oil pump
Description
Specification
Clearance between outer circumference and front case.
0.12-0.18 mm
(0.0047-0.0070 in.)
Front case tip clearance
|
Side clearance
|
Inner gear
0.02-0.065 mm
(0.0008-0.0025 in.)
Outer gear
0.02-0.07 mm
(0.008-0.0027 in.)
Engine oil pressure at engine idle speed
[Oil temperature is 90 to 100°C (194 to 215°F)]
166 KPa
(1.7 kg/cm2, 24.2 psi)
Relief spring (Free height)
43.8 mm (1.724 in.)
Relief spring (Load)
3.7 kg at 40.1 mm
(8.15 Ib/1.578 in.)
Air cleaner
Description
Specification
Type
Dry type
Element
Unwoven cloth type
Exhaust pipe
Description
Specification
Muffler
Expansion resonance type
Suspension system
Rubber hangers
Valve
Description
Specification
Valve length (Intake)
102.34 mm (4.029 in.)
Valve length (Exhaust)
104.8 mm (4.1259 in.)
Stem O.D. (Intake)
5.965-5.98 mm
(0.2348-0,2354 in.)
Stem O.D. (Exhaust)
5.93-5.95 mm
(0.2334-0.2342 in.)
Face angle thickness of valve head (Margin)
Description
Specification
Limit
Intake
1.15 mm
(0.0452 in.)
0.8 mm (0.031 in.)
Exhaust
1.35 mm
(0.0531 in.)
1.0 mm (0.039 in.)
Valve stem to valve guide clearance
Description
Specification
Limit
Intake
0.02-0.05 mm
(0.0008-0.0019 in.)
0.10 mm
(0.0039 in.)
Exhaust
0.05-0.085 mm
(0.0019-0.0033 in.)
0.15 mm
(0.059 in.)
Valve guide
Description
Specification
Installed dimension O.D. (Intake)
11 mm (0.433 in.)
Installed dimension O.D. (Exhaust)
11 mm ( 0.433 in.)
Service size
0.05, 0.25, 0.50 mm, (0.002, 0.010, 0.020 in.) oversize
Valve seat
Description
Specification
Width of seat contact (Intake)
1.1-1.5 mm (0.043-0.059 in.)
Width of seat contact (Exhaust)
1.3-1.7 mm (0.051-0.066 in.)
Seat angle
45°
Oversize
0.3, 0.6 mm
(0.012, 0.024 in.) oversize
Valve spring
Description
Specification
Free length
46.07 mm (1.8137 in.)
Load
25.5 kg/37 mm 57.3 kg/28 mm
Installed height
37 mm (1.456 in.)
Squareness
1.5° or less
Valve timing
Description
Specification (1.8L)
Specification (2.0L)
Intake valve: Opens (BTDC)
6°
8°
Intake valve: Closes (ABDC)
46°
40°
Exhaust valve: Opens (BBDC)
50°
50°
Exhaust valve: Closes (ATDC)
10°
10°
Cylinder head
Description
Specification
Limit
Flatness of gasket surface
Max. 0.05 mm
(0.0020 in.)
0.1 mm
(0.0039 in.)
Flatness of manifold mounting surface
Max. 0.15 mm
(0.0059 in.)
0.3mm
(0.0118 in.)
Oversize rework dimensions of valve seat hole (Intake)
0.3 mm (0.012 in.) O.S.
0.6 mm (0.024 in.) O.S.
33.300-33.325 mm
(1.3110-1.3120 in.)
33.600-33.625 mm
(1.3228-1.3238 in.)
Oversize rework dimensions of valve seat hole (Exhaust)
0.3 mm (0.012 in.) O.S.
0.6 mm (0.024 in.) O.S.
28.800-28.821 mm
(1.1338-1.1346 in.)
29.100-29.121 mm
(1.1456-1.1465 in.)
Oversize rework dimensions of valve guide hole (both intake and exhaust)
0.05 mm (0.002 in.) O.S.
11.05-11.068 mm
(0.435-0.4357 in.)
0.25 mm (0.010 in.) O.S.
11.25-11.268 mm
(0.443-0.4436 in.)
0.50 mm (0.020 in.) O.S.
11.50-11.518 mm
(0.453-0.4535 in.)
This post has been edited by aussiedeuce: 15 January 2012 - 09:10 AM
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