SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2000
GROUP
Engine Mechanical System Engine Block
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INSPECTION 
Cylinder Block
  1. Visually check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Repair or replace the block if defective.

  1. Using a straight edge and feeler gauge, check the block top surface for warp. Make sure that the surface is free from gasket chips or other foreign objects.

    MEASUREMENT SPECIFICATION
    Block Top Surface Warp 0.05 mm ( 0.0020 or less in )
    MEASUREMENT SPECIFICATION
    Block Top Surface Warp 0.1 mm ( 0.0039 in )
  1. Measure the cylinder bore with a cylinder gauge at three levels in the directions A and B. If the cylinder bores show more than the specified out-of round or taper or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize pistons and rings must be fitted. Measuring points are as shown.

    SPECIFICATION
    Cylinder I.D 75.5 mm (2.972 in.)
    SPECIFICATION
    Cylinder I.D taper 0.02 mm (0.0008 in.) or less
  1. If a cylinder ridge exists, cut away with a ridge reamer.

  1. Oversize pistons are available in four sizes

    SPECIFICATION
    Piston service size and mark (O.S.) 0.25 mm (0.010 in.)
    SPECIFICATION
    Piston service size and mark (O.S.) 0.50 mm (0.020 in.)
    SPECIFICATION
    Piston service size and mark (O.S.) 0.75 mm (0.030 in.)
    SPECIFICATION
    Piston service size and mark (O.S.) 1.00 mm (0.039 in.)
  1. When boring the cylinder bore to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize.

    The standard measurement of the piston outside diameter is taken at a level 12 mm (0.47 in.) above the bottom of the piston skirt and across the thrust faces.

    SPECIFICATION
    Piston-to-cylinder wall clearance 0.025-0.045 mm (0.0008-0.0016 in.)
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CYLINDER BLOCK 
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DISASSEMBLY 
  1. Remove the cylinder head, timing belt, front case, flywheel, piston and crankshaft.

    For further details, refer to the respective chapters.