SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Engine Mechanical System Cylinder Head Assembly
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INSPECTION 
  1. Check the cylinder head for cracks, damage and coolant leakage.

  1. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged.

  1. Check the cylinder head surface for flatness by using a straight edge from the direction of A, B, .... as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface.

    MEASUREMENT SPECIFICATION
    Cylinder head surface flatness Less than 0.05 mm ( 0.002 in )
    MEASUREMENT SPECIFICATION
    Cylinder head surface flatness 0.1 mm ( 0.0040 in )
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CHECKING COMPRESSION PRESSURE 
  1. Before checking compression, check the engine oil level. Make sure the starter motor and battery are in normal operating condition.

    NOTE
    Always use a fully-charged battery to obtain specified engine revolution.
  1. Start the engine and wait until engine coolant temperature reaches 80-95°C (176-205°F)

  1. Stop the engine and disconnect the spark plug cables.

  1. Remove the spark plugs.

  1. Crank the engine to remove any foreign objects in the cylinders.

  1. Screw the compression gauge into the spark plug hole.

  1. Fully open the throttle.

  1. Crank the engine and read the gauge.

    Standard value [at 250-400rpm]
    		 14.5kg/cm2 (1.47Mpa, 213psi)
    Limit
    		 13kg/cm2 (1.37Mpa, 199psi)
  1. Repeat steps 6 through 8 on all cylinders, making sure that the pressure differential for each of the cylinders is within the specified limit.

    Limit
    		 Max.l.0 kg/cm2 (100kpa, 14psi) between cylinders
  1. If a cylinder's compression or pressure differential is below the specification, add a small mount of oil through the spark plug hole and repeat steps 6 through 9.

    1. If the addition of oil brings the compression up, it is possible that there is wear between the piston ring and cylinder wall.
    1. If compression remains the same, valve seizure, poor valve seating or a compression leak from the cylinder head gasket are all possible causes.
    1. If compression in any two adjacent cylinder is low and if adding oil does not help compression, there is leakage past the gasket surface. If so, replace cylinder head gasket.
      TORQUE SPECIFICATION
      Spark plug 20-30 Nm ( 200-300 kg·cm, 15-21 lb·ft )
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COMPONENTS 
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DISASSEMBLY 
  1. Drain the coolant and disconnect the upper radiator hose.

  1. Remove the breather hose (between the air cleaner and the head cover).

  1. Remove the air-intake hose.

  1. Remove the vacuum hose, fuel hose and coolant hose.

  1. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.

  1. Remove the ignition coil.

  1. Remove the power steering oil pump and bracket.

  1. Remove the intake manifold.

  1. Remove the heat protector and exhaust manifold assembly.

  1. Remove the coolant pump pulley and the crankshaft pulley.

  1. Remove the timing belt cover.

  1. Remove the timing belt tensioner pulley.

  1. Remove the timing belt.

  1. Remove the head cover.

  1. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool, Cylinder Head Bolt Wrench (09221-32001, 09221-11000), in the sequence as shown in the illustration in two or three steps.

  1. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface.

    NOTE
    Make sure that the gasket pieces do not fall in the engine.
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DISASSEMBLY 
  1. Clean all gasket surfaces of the cylinder block and the cylinder head.

  1. Install a new cylinder head gasket onto the cylinder head assembly. sealant to the gasket and do not reuse the old cylinder head gasket.

  1. Install the cylinder head bolts. Starting at top center, tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench (09221-11001 ). Repeat the procedure, retightening all cylinder head bolt to the specified torque.

    Cylinder head bolt
    M10
    		 30Nm (300kg.cm,221b.ft)+(60°-65°)+(60°-65°)
    M12
    		 35Nm (350kg.cm,261b.ft)+(60°-65°)+(60°-65°)
    NOTE
    When tightening the cylinder head bolt, using special tool and torque wrench, tighten the bolt to the specified torque [M10:30 Nm, M12: 35 Nm] and then turn the torque wrench 60°-65° and repeat it one more time as shown in illustration.
  1. Install the timing belt tensioner pulley.

  1. Install the timing belt on the camshaft sprocket, making sure that the tension side is tightened by turning the camshaft sprocket in reverse, all timing marks are in alignment.

  1. Adjust the timing according to "Timing Belt"

  1. Install the rocker cover and tighten the bolts to the specified torque.

    TORQUE SPECIFICATION
    Rocker cover belt 8-10 Nm ( 80-100 kg·cm, 5.9-7.4 lb·ft )
  1. Install the timing belt cover.

  1. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.

  1. Install the new exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the specified torque.

  1. Install the surge tank and tighten the nuts bolts to the specified torque.

    TORQUE SPECIFICATION
    Manifold nuts and bolts (both intake and exhaust) 15-20 Nm ( 150-200 kg·cm, 11-14 lb·ft )
    TORQUE SPECIFICATION
    Surge tank to inlet manifold nuts and bolts 15-20 Nm ( 150-200 kg·cm, 11-14 lb·ft )
  1. Install the power steering oil pump and bracket.

  1. Install the ignition coil.

  1. Install the air intake hose.

  1. Connect the vacuum hose, fuel hose and water hose.

  1. Install breather hose.