Applies to: Hyundai Coupe/Tiburon 1998-2001
Engine Mechanical System Main Moving System
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  1. Remove the timing belt, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective chapters.

  1. Remove the rear plate and the rear oil seal.

  1. Remove the connecting rod caps.

    Mark the main bearing caps to permit reassembly in the original position and direction.
  1. Remove the main bearing caps and remove the crankshaft. Keep the bearings in order by cap number.

  1. Remove the crankshaft position sensor wheel.

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  1. Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging. Correct or replace any defective part.

  1. Inspect out-of-roundness and taper of crankshaft journal and pin.

    Crankshaft journal O.D. 50 mm ( 1.9685 in )
    Crankshaft pin O.D. 45 mm ( 1.7717 in )
    Crankshaft journal, pin out-of-roundness and taper 0.01 mm ( 0.0004 in )
Main Bearings and Connecting Rod Bearings

Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace the defective bearings.

Oil Clearance Measurement

To check the oil clearance, measure outside diameter of the crankshaft journal and the crank pin and inside diameter of the bearing. The clearance measurement is the difference between the measured outside and inside diameters.

Crankshaft main bearing 0.028-0.048 mm ( 0.0011-0.0018 in )
Connecting rod bearing. 0.024-0.044 mm ( 0.0009-0.0017 in )
Crankshaft main bearing 0.1 mm ( 0.0039 in )
Connecting rod bearing. 0.1 mm ( 0.0039 in )
Oil Clearance Measurement (Plastigauge Method)

Plastigauge may be used to measure the clearance.

  1. Remove oil, grease and any other dirt from bearings and journals.

  1. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, away from oil holes.

  1. Install the crankshaft, bearings, and caps. Tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastigauge at the widest point using the scale printed on the gauge package. If the clearance exceeds the repair limit, the bearing should be replaced or an undersize bearing be used. When installing a new crankshaft, be sure to use standard size bearings. Should the standard clearance not be obtained even after bearing replacement, the journal should be ground to a recommended under size, and a bearing of the same size should be installed.

Oil Seal

Check front and rear oil seals for damage or worn lips. Replace any defective seat.

Bearing Caps

After installing the bearing caps, make sure that the crankshaft turns smoothly and the end play is correct. If the end play exceeds the limit, replace crankshaft bearing.

Bearing caps end play 0.06-0.26 mm ( 0.0023-0.010 in )
Bearing caps end play 0.30 mm ( 0.0118 in )
Sensor wheel
  1. Remove the crankshaft sensor wheel.

  1. Check the crankshaft sensor wheel for damage, cracks and wear. Replace if necessary.

  1. Check the clearance between crankshaft sensor wheel and crank position sensor with depth gage.

    Clearance between crankshaft sensor wheel and crank position sensor 0.5-1.5 mm ( 0.020-0.059 in )
    1. Measure the depth of the top of sensor wheel tooth and the outside of transaxle housing.
    2. Measure the difference between sensor length and depth.
    3. Sensor length is the distance between the end of sensor and inner point of contacting face.
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  1. Install the upper main bearing inserts in the cylinder block.

    When reusing the main bearings, remember to install them by referring to the location marks made at the time of disassembly.
  1. Install the crankshaft. Apply engine oil to the journals.

  1. Install bearing caps and tighten cap bolts to the specified torque in the sequence of the center, No.2, No.4 front and rear caps. Cap bolts should be tightened evenly in 2 to 3 stages before they are tightened to the specified torque. The caps should be installed with the arrow mark directed toward the crank pulley side of engine. Cap numbers must be corrected.

    Main bearing cap bolt 55-60 Nm ( 550-600 kg·cm, 40-43.4 lb·ft )
    Connecting rod cap bolt 32-35 Nm ( 320-350 kg·cm, 23-28 lb·ft )
  1. Make certain that the crankshaft turns freely and has the proper clearance between the center main bearing thrust flange and the connecting rod big end bearing.

    Crankshaft end play 0.05-0.175 mm ( 0.002-0.005 in )
  1. Install the oil seal in the crankshaft rear oil seal case. Use Special Tool, Crankshaft Rear Oil Seal Installer (0923111000) as shown. Press fit the oil seal all the way in, being careful not to misalign it.

  1. Install the rear plate and tighten the bolts.

  1. Install the connecting rod caps. Refer to "Piston and Connecting Rods".

  1. Install the flywheel, front case, oil pan and timing belt. For further details, refer to the respective chapters.