SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Engine Mechanical System Lubrication System
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COMPONENTS 
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DISASSEMBLY 
  1. Remove the timing belt. Refer to "Timing Belt."

  1. Remove all the oil pan bolts.

  1. Remove the oil pan.

  1. Remove the oil screen.

  1. Remove the front case assembly.

  1. Remove the oil pump cover.

  1. Remove the inner and outer gears from the front case. The mating marks on the inner and outer gears indicate the direction of installation. Make sure that the inner and outer gears are installed as shown.

  1. Remove the plug and remove the relief spring and relief plunger.

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INSPECTION 
Front Case
  1. Check the front case for cracks or damage. Replace as necessary.

  1. Check the front oil seal for worn or damaged lips. Replace if defective.

Oil Pan and Oil Screen
  1. Check the oil pan for failure, damage or cracks. Replace if defective.

  1. Check the oil screen for failure, damage and cracks and replace if defective.

Front Case and Oil Pump Cover

Worn (especially stepped) or damaged surfaces contacting gears.

OIL PUMP GEARS
  1. Worn or damaged gear tooth surfaces.

  1. Clearance between outer gear and front case.

    Outer gear
    Clearance between outer circumference and front case
    		 0.12-0.185mm (0.005-0.007 in.)
  1. Check the tip clearance on the pump rotor

    MEASUREMENT SPECIFICATION
    Tip clearance on the pump rotor 0.025-0.069 mm ( 0.001-0.003 in )
  1. Check the axial clearance on the outer pump rotor

    MEASUREMENT SPECIFICATION
    Axial clearance on the outer pump rotor 0.06-0.11 mm ( 0.0024-0.0043 in )
  1. Check the axial clearance on the inner pump rotor.

    MEASUREMENT SPECIFICATION
    Axial clearance on the inner pump rotor 0.04-0.085 mm ( 0.0018-0.0033 in )
Relief Valve and Spring
  1. Check sliding condition of the relief valve inserted in the front case.

  1. Inspect for distorted or broken relief valve spring.

    Standard value
    Free height
    		 43.8 mm (1.724 in.)
    Load
    		 3.7 kg/40.1 mm (8.14 lb/1.579 in.)
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REASSEMBLY 
Oil Pump
  1. Install the outer and inner gears into the front case. Make sure that the inner and outer gears are installed in the same direction as shown.

  1. Install the oil pump cover and tighten the bolts to the specified torque. After the bolts have been tightened, check to ensure that the gear turns smoothly.

    TORQUE SPECIFICATION
    Oil pump cover bolt 6-9 Nm ( 60-90 kg·cm, 4-6.6 lb·ft )
  1. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.

    TORQUE SPECIFICATION
    Relief valve plug 40-50 Nm ( 400-500 kg·cm, 29-36 lb·ft )
Front Case

Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.

Body length
A
 25 mm (0.98 in
B
 20 mm (0.787 in
C
 38 mm (1.496 in
D
 45 mm (1.771 in.
TORQUE SPECIFICATION
Front case assembly new gasket torque 20-27 Nm ( 200-270 kg·cm, 14.5-19.8 lb·ft )
OIL SEAL
  1. Inspect for worn, distorted spring lips.

  1. Check for elongated spring ring.

  1. Always use a new oil seal when reassembling.

  1. Use Special Tool, Mounting Bushing Remover and installer Arbor (09216-21000), install the oil seal.

  1. Install the crankshaft sprocket, timing belt and crankshaft pulley. Refer to "Timing Belt".

  1. Install the oil screen.

  1. Clean both gasket surfaces of the oil pan and the cylinder block.

  1. Apply sealant into the groove of the oil pan flange as shown.

    CAUTION
    1. Apply sealant approx. 4 mm (0.16 in.) in thickness.
    1. After application of sealant, do not exceed 15 minutes before installing the oil pan.
  1. Install the oil pan and tighten the bolts to the specified torque.

    TORQUE SPECIFICATION
    Oil pan bolt 6-8 Nm ( 60-80 kg·cm, 4-6 lb·ft )