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Tiburon Service Manual - G4GF/G4GM Engine specs

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Old 01-07-2012, 04:19 AM
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Default Tiburon Service Manual - G4GF/G4GM Engine specs

HAD ACCESS TO THIS. FRIKN SITE KEEPS TIMING ME OUT NOW!!!

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.)
Old 01-07-2012, 04:34 AM
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Manual Topics: (Section 1)



Body (Interior & Exterior)

General

SPECIAL TOOLS

SPECIFICATIONS

TIGHTENING TORQUE

BODY DIMENSIONS

BODY DIMENSIONS

BODY DIMENSIONS

BODY DIMENSIONS

BODY DIMENSIONS

BODY DIMENSIONS

TROUBLESHOOTING

Windshield & Rear Window

Windshield

COMPONENTS

REMOVAL

INSTALLATION

Sunroof/Moonroof

COMPONENTS

REMOVAL AND INSTALLATION

ADJUSTMENT

Rear Window Glass

COMPONENTS

REMOVAL

INSTALLATION

Seats

Seat Belt

COMPONENTS

REMOVAL AND INSTALLATION

Front Seat

COMPONENTS

REMOVAL AND INSTALLATION

Rear Seat

COMPONENTS

REMOVAL AND INSTALLATION

Hood, Doors & Trunk Lid

Door Glass

GLASS ADJUSTMENT

Front Door

COMPONENTS

DOOR POSITION ADJUSTMENT

DOOR STRIKER ADJUSTMENT

INSIDE DOOR HANDLE ADJUSTMENT

REMOVAL AND INSTALLATION

Hood

COMPONENTS

REMOVAL AND INSTALLATION

ADJUSTMENT

Trunk Lid/Tailgate

COMPONENTS

REMOVAL AND INSTALLATION

ADJUSTMENT

Grille, Molding & Bumpers

Bumper

FRONT BUMPER COMPONENTS

REMOVAL AND INSTALLATION

REAR BUMPER COMPONENTS

REMOVAL AND INSTALLATION

Fenders

Fender

COMPONENTS

REMOVAL AND INSTALLATION

Body Side Moldings

COMPONENTS

REMOVAL AND INSTALLATION

Console & Interior Trim

Console

COMPONENTS

REMOVAL AND INSTALLATION

Interior Trim

COMPONENTS

REMOVAL AND INSTALLATION

Crash Pad

COMPONENTS

REMOVAL

INSTALLATION

Body Paneling & Side Glass

Quarter Glass

COMPONENTS

REMOVAL

INSTALLATION
Old 01-07-2012, 04:36 AM
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I will clean up the format before I post the next pages.
Old 01-07-2012, 09:50 AM
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aussie... before you continue posting, I want to make sure you're aware of Hyundai's Webtech?



http://www.HMAservice.com



login:pw = GenesisCoupe : GenesisCoupe
Old 02-04-2012, 01:06 PM
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Originally Posted by majik
aussie... before you continue posting, I want to make sure you're aware of Hyundai's Webtech?



http://www.HMAservice.com



login:pw = GenesisCoupe : GenesisCoupe


They are on to you.
Old 02-04-2012, 09:45 PM
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Logins sometimes stop working, even recently-made group logins. Fortunately hyundaitechinfo (=webtech =hmaservice) gives away free logins for the asking. Mine's BEEN working.



It is also the more frequently used thing for which I use Internet Exploder, so I set my homepage to hyundaitechinfo's login screen to save time.
Old 02-04-2012, 10:00 PM
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The Canadian site works well with FireFox but sends you to the US site for TSBs and such. The US site is my IE homepage as that is all I use it for.
Old 02-05-2012, 09:38 AM
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Hey, surely webtech isn't the only thing you can use IE for, right?





























































Right?
Old 02-05-2012, 11:32 AM
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It also works with PayPal, but my Firefox sucks with paypal. That's all I can recall using IE for in the last I don't know how long.




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