Page 1 Engine Mechanical System (DOHC 1.6L) - Accent GENERAL SPECIFICATION Fig. 1: Specification Table (1 Of 4) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. viernes, 19 de febrero de 2021 07:13:03 a. m. Page 1 Page 1 ©...
Page 2 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 2: Specification Table (2 Of 4) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Page 3 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 3: Specification Table (3 Of 4) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 3 © 2011 Mitchell Repair Information Company, LLC.
Page 4: Tightening Torque
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 4: Specification Table (4 Of 4) Courtesy of HYUNDAI MOTOR CO. NOTE: O.D. = Outer Diameter I.D. = Inner Diameter O.S. = Oversize Diameter U.S. = Undersize Diameter...
Page 5 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Step 5 Tighten An Additional 90 Degrees Driveplate/Flywheel Bolts Automatic Transmission 89-96 (120-130) Manual Transmission 89-96 (120-130) Engine Mounts Front Engine Support Bracket Fasteners 33-41 (45-55) Front Engine Support Bracket Stay Bolt...
Page 6 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Oil Pan Bolts 89-106 (10-12) Oil Pressure Switch 10-11 (13-45) Resonator Mounting Bolt 27-35 (4-6) Timing Belt Cover Bolt 71-89 (8-10) Tighten cylinder head bolts in sequence. See Fig. 5.
Page 7 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 5: Identifying Cylinder Head Tightening Sequence Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 7 © 2011 Mitchell Repair Information Company, LLC.
Page 8: Service Standard
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent SERVICE STANDARD Fig. 6: Service Standard Courtesy of HYUNDAI MOTOR CO. SPECIAL TOOLS viernes, 19 de febrero de 2021 07:12:57 a. m. Page 8 © 2011 Mitchell Repair Information Company, LLC.
Page 9 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 7: Identifying Special Tools (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 9 © 2011 Mitchell Repair Information Company, LLC.
Page 10: Troubleshooting
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 8: Identifying Special Tools (2 Of 2) Courtesy of HYUNDAI MOTOR CO. TROUBLESHOOTING viernes, 19 de febrero de 2021 07:12:57 a. m. Page 10 © 2011 Mitchell Repair Information Company, LLC.
Page 11 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 9: Troubleshooting Table (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 11 © 2011 Mitchell Repair Information Company, LLC.
Page 12: Checking Engine Oil
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 10: Troubleshooting Table (2 Of 2) Courtesy of HYUNDAI MOTOR CO. MAINTNENCE CHECKING ENGINE OIL 1. Position the vehicle on a level surface. 2. Warm up the engine.
Page 13: Changing Engine Oil
3. Remove the oil filler cap and the drain plug (on the oil pan). Drain the engine oil. Fig. 12: Identifying Drain Plug Courtesy of HYUNDAI MOTOR CO. 4. Install and tighten the drain plug to the specified torque. Tightening torque Drain plug: 35-45Nm (350-450 kg.cm, 24-33 lb.ft)
Page 14: Filter Selection
8. Turn off the engine and then check the oil level. Add oil if necessary. FILTER SELECTION All Hyundai engines are equipped with a high quality, disposable oil filter. This filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters should be used to assure the most efficient service.
Page 15 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 13: Locating Oil Filter Part Number Courtesy of HYUNDAI MOTOR CO. PROCEDURE FOR REPLACING THE OIL FILTER CAUTION: Be careful not to burn yourself, as the engine and engine oil are hot.
Page 16 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 14: Installing Oil Filter Courtesy of HYUNDAI MOTOR CO. 3. Tighten the oil filter to the specified torque. Tightening torque Oil filter: 12 - 16 Nm (120 - 160 kg.cm, 9 - 12 lb.ft) 4.
Page 17 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 15: Recommended SAE Viscosity Grades Courtesy of HYUNDAI MOTOR CO. NOTE: For best performance and maximum protection of all types of operation, select only those lubricants which: NOTE: 1.
Page 18 4. If there is leakage, repair or replace with the appropriate part. Fig. 16: Pressure Testing Cooling System Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:57 a. m. Page 18...
Page 19: Radiator Cap Pressure Test
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent RADIATOR CAP PRESSURE TEST 1. Use an adapter to attach the cap to the tester. 2. Increase the pressure until the gauge stops moving. Main valve opening pressure: 83-110 kPa (0.83-1.1 kg/cm...
Page 20: Specific Gravity Test
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 17: Pressure Testing Radiator Cap Courtesy of HYUNDAI MOTOR CO. SPECIFIC GRAVITY TEST 1. Measure the specific gravity of the coolant with a hydrometer. 2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using Fig.
Page 21: Relation Between Coolant Concentration And Specific Gravity
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 18: Inspecting Coolant Specific Gravity Courtesy of HYUNDAI MOTOR CO. RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY viernes, 19 de febrero de 2021 07:12:57 a. m.
Page 22: Checking Compression Pressure
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 19: Relation Between Coolant Concentration & Specific Gravity Courtesy of HYUNDAI MOTOR CO. Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F)
Page 23 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 5. Crank the engine to remove any foreign material in the cylinders. 6. Insert the compression gauge into the spark plug hole. 7. Depress the accelerator pedal to open the throttle fully.
Page 24: Adjusting Timing Belt Tension
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 21: Checking Compression Courtesy of HYUNDAI MOTOR CO. ADJUSTING TIMING BELT TENSION 1. Lift the vehicle by using of jack. 2. Rotate the steering wheel counter-clockwise thoroughly.
Page 25 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 22: Identifying Engine Support Bracket Courtesy of HYUNDAI MOTOR CO. 4. Remove the water pump pulley. 5. Remove the timing belt upper cover. viernes, 19 de febrero de 2021 07:12:57 a. m.
Page 26 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 23: Identifying Timing Belt Upper Cover Courtesy of HYUNDAI MOTOR CO. 6. Remove the spark plug. 7. Place the piston of No.1 cylinder to TDC of the compression stroke by rotating the crankshaft clockwise.
Page 27 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 24: Locating Idler & Tensioner Pulley Courtesy of HYUNDAI MOTOR CO. 8. Loosen the tensioner bolt of pivot side and slot side. 9. Rotate the crankshaft clockwise as many as 2 teeth of sprocket.
Page 28: Adjusting Drive Belt Tension
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 25: Tightening Bolt Courtesy of HYUNDAI MOTOR CO. 10. Check that the teeth of sprocket and belt coincide with each other. 11. Tighten the bolt of slot side of first and then tighten the bolt of pivot side.
Page 29: Standard Value
Also check the amount that the belt is deflected. Fig. 26: Verifying Belt Installation Courtesy of HYUNDAI MOTOR CO. STANDARD VALUE: viernes, 19 de febrero de 2021 07:12:57 a. m.
Page 30 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 27: Standard Value Table Courtesy of HYUNDAI MOTOR CO. NOTE: 1. The belt tension must be measured half - way between the specified pulleys. 2. When a new belt is installed, adjust the tension to the central value of the standard range indicated under "New"...
Page 31 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 28: Locating Engine Pulleys Courtesy of HYUNDAI MOTOR CO. TYPE A TENSION GAUGE Do not let the dial section of the tension gauge contact other objects during measurement.
Page 32 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 29: Identifying Type A Tension Gauge Courtesy of HYUNDAI MOTOR CO. TYPE B TENSION GAUGE 1. When measuring, turn the reset button in the direction of the arrow and set the gauge needle to the RESET position.
Page 33: Adjusting The Alternator Belt
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 30: Identifying Type B Tension Gauge Courtesy of HYUNDAI MOTOR CO. ADJUSTING THE ALTERNATOR BELT CAUTION: If the belt is too loose, it will cause noise or sudden wear.
Page 34: Engine Block
12-15 Nm (120-150 kg.cm, 9-11 lb.ft) Alternator brace mounting bolt: 20-27 Nm (200-270 kg.cm, 15-20 lb.ft) Fig. 31: Adjusting Alternator Belt Courtesy of HYUNDAI MOTOR CO. ENGINE BLOCK ENGINE BLOCK COMPONENTS viernes, 19 de febrero de 2021 07:12:57 a. m.
Page 35 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 32: Engine Block Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Remove the cylinder head, timing belt, front case, flywheel, pistons and crankshaft. 2. Remove the oil pressure switch.
Page 36: Cylinder Block
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 33: Removing Oil Pressure Switch Courtesy of HYUNDAI MOTOR CO. CYLINDER BLOCK 1. Check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Replace the block if defective.
Page 37 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 34: Checking Top Surface Of Block For Warpage Courtesy of HYUNDAI MOTOR CO. 3. Measure the cylinder bore with a cylinder gauge at three levels in the direction of 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.
Page 38 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 35: Measuring Cylinder Bore Diameter Courtesy of HYUNDAI MOTOR CO. 4. If a cylinder ridge exists, cut away with a ridge reamer. 5. Oversize pistons are available in four sizes.
Page 39: Engine Mounts
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 6. When boring the cylinder to the oversize, maintain the specified clearance between the oversize piston and the bore, and make sure that all pistons used are the same oversize.
Page 40 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 36: Engine Mounts Components Courtesy of HYUNDAI MOTOR CO. REMOVAL 1. Attach an engine hoist to the engine hooks, and raise the engine just enough so that there is no pressure on the insulators.
Page 41: Engine Mounting
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 37: Attaching Engine Hoist To Engine Hooks Courtesy of HYUNDAI MOTOR CO. ENGINE MOUNTING 1. Remove the engine mounting insulator bolts. 2. Remove the engine mounting bracket from the engine.
Page 42: Transmission Mounting
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 38: Identifying Engine Mounting Bracket Courtesy of HYUNDAI MOTOR CO. TRANSMISSION MOUNTING 1. For vehicles with a 5-speed manual transmission, remove the select control valve. 2. Remove the transmission mounting bolt.
Page 43 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 39: Identifying Transmission Mounting Bolt Courtesy of HYUNDAI MOTOR CO. 3. Detach the cap from inside the right fender shield. Remove the transmission mounting bolts. 4. Remove the transmission bracket.
Page 44 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 40: Detaching Cap From Inside Right Fender Shield Courtesy of HYUNDAI MOTOR CO. FRONT ROLL STOPPER 1. Remove the front roll stopper bracket from the subframe.
Page 45 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 41: Identifying Front Roll Stopper Bracket Courtesy of HYUNDAI MOTOR CO. REAR ROLL STOPPER 1. Remove the rear roll stopper from the subframe. viernes, 19 de febrero de 2021 07:12:58 a. m.
Page 46 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 42: Identifying Rear Roll Stopper Courtesy of HYUNDAI MOTOR CO. INSTALLATION TRANSMISSION MOUNTING 1. Verify that the stopper is correctly inserted into the inner pipe in order not to move.
Page 47 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 43: Installing Stopper Courtesy of HYUNDAI MOTOR CO. FRONT ROLL STOPPER 1. Install the insulator in the correct angle. A/T: 30 +/- 3° M/T: 14 +/- 3°...
Page 48 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 44: Installing Insulator In Correct Angle - Front Courtesy of HYUNDAI MOTOR CO. REAR ROLL STOPPER 1. Install the insulator in the correct angle. A/T: 33 +/- 3°...
Page 49 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent M/T: 20 +/- 3° Fig. 45: Installing Insulator In Correct Angle - Rear Courtesy of HYUNDAI MOTOR CO. MOUNTING BUSHING NOTE: The front and rear cross member mounting bushings are directional.
Page 50 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 46: Locating Lateral Member Arrow Mark (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:58 a. m. Page 50 © 2011 Mitchell Repair Information Company, LLC.
Page 51 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 47: Locating Lateral Member Arrow Mark (2 Of 2) Courtesy of HYUNDAI MOTOR CO. NOTE: Make sure the bushings are positioned parallel to the lateral member of the cross member.
Page 52 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 48: Identifying Air Cleaner Courtesy of HYUNDAI MOTOR CO. 3. Disconnect the connectors for the backup lamp switch and engine harness. 4. For vehicles with a 5-speed manual transmission, disconnect the select control valve connector.
Page 53 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 49: Removing Hose Clamp Courtesy of HYUNDAI MOTOR CO. NOTE: When disconnecting hoses, make identification marks to ensure they are reconnected correctly. CAUTION: Be careful not to spill oil or fluid from hoses. Plug the openings to prevent foreign material from entering.
Page 54 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 16. Disconnect the air conditioner compressor from the mounting bracket. Fig. 50: Removing Air Conditioner Compressor Courtesy of HYUNDAI MOTOR CO. 17. Jack up the vehicle. 18. Drain the transmission oil (or fluid).
Page 55 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 51: Locating Transmission Oil Drain Plug Courtesy of HYUNDAI MOTOR CO. 19. Disconnect the front exhaust pipe from the manifold. NOTE: Use wire to suspend the exhaust pipe from the bottom of the vehicle.
Page 56 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 52: Locating Drive Shaft Oil Seal Courtesy of HYUNDAI MOTOR CO. CAUTION: Plug the axle holes of the transmission case to prevent entry of foreign material.
Page 57 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 53: Identifying Front Roll Stopper Courtesy of HYUNDAI MOTOR CO. 26. Separate the rear roll stopper. viernes, 19 de febrero de 2021 07:12:58 a. m. Page 57...
Page 58 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 54: Identifying Rear Roll Stopper Courtesy of HYUNDAI MOTOR CO. 27. Remove the engine mounting insulator bolts. 28. Remove the engine mounting bracket from the engine.
Page 59 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 55: Identifying Engine Mounting Bracket Courtesy of HYUNDAI MOTOR CO. 29. Slowly raise the engine (to the extent that the weight of the engine and transmission assembly is not applied to the mounting portions) and temporarily hold it in the raised position.
Page 60 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 56: Removing Caps From Inside Of Right Fender Shield Courtesy of HYUNDAI MOTOR CO. 31. While directing the transmission side downward, lift the engine and transmission assembly up and out of the vehicles.
Page 61 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 57: Cam Shaft Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Disconnect the breather hose and the PCV hose. 2. Remove the coolant pump pulley and crankshaft pulley.
Page 62 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 58: Removing Coolant Pump Pulley & Crankshaft Pulley Courtesy of HYUNDAI MOTOR CO. 3. Remove the timing belt cover. 4. Loosen the timing belt tensioner pulley and temporarily secure it.
Page 63 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 59: Identifying Cylinder Head Cover Courtesy of HYUNDAI MOTOR CO. 9. Remove the camshaft sprocket. 10. Remove the camshaft bearing caps and timing chain. viernes, 19 de febrero de 2021 07:12:58 a. m.
Page 64 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 60: Removing Camshaft Courtesy of HYUNDAI MOTOR CO. 11. Remove the camshaft. 12. Remove the HLA. (Hydraulic lash adjuster) INSPECTION CAMSHAFTS 1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.
Page 65 Exhaust: 43.3489 mm (1.7066 in.) Fig. 61: Checking Cam Lobes For Damage Courtesy of HYUNDAI MOTOR CO. 3. Check the cam surface for abnormal wear or damage, and replace if necessary. 4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.
Page 66 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Camshaft end play: 0.1-0.15 mm (0.0039-0.0059 in.) OIL SEAL 1. Check the lips for wear. If the lip threads are worn, replace. 2. Check the oil seal lip contacting surface of the camshaft. If it is worn, replace the camshaft.
Page 67 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent viernes, 19 de febrero de 2021 07:12:58 a. m. Page 67 © 2011 Mitchell Repair Information Company, LLC.
Page 68 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 62: Identifying Oil Seal Courtesy of HYUNDAI MOTOR CO. HLA (HYDRAULIC LASH ADJUSTER) With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
Page 69 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 63: Checking HLA (Hydraulic Lash Adjuster) viernes, 19 de febrero de 2021 07:12:58 a. m. Page 69 © 2011 Mitchell Repair Information Company, LLC.
Page 70: Timing Chain
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Courtesy of HYUNDAI MOTOR CO. Fig. 64: Troubleshooting Table Courtesy of HYUNDAI MOTOR CO. TIMING CHAIN Check the bushing and plate of timing chain for wear. Replace if wear is severe.
Page 71 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 65: Identifying Timing Chain Courtesy of HYUNDAI MOTOR CO. REASSEMBLY 1. Install the HLA. 2. Align the camshaft timing chain with intake timing chain sprocket and exhaust timing chain sprocket as shown.
Page 72 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 66: Identifying Timing Chain Sprockets Courtesy of HYUNDAI MOTOR CO. 3. Install the camshaft after lubricating the camshaft journals with engine oil. viernes, 19 de febrero de 2021 07:12:58 a. m.
Page 73 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 67: Installing Camshaft Courtesy of HYUNDAI MOTOR CO. 4. Install the bearing caps. The markings on the caps are for intake/exhaust identification. I: Intake camshaft E: Exhaust camshaft viernes, 19 de febrero de 2021 07:12:58 a.
Page 74 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 68: Identifying Bearing Cap Number Courtesy of HYUNDAI MOTOR CO. 5. Tighten the bearing caps to the specified torque in two or three steps as shown. Tightening torque Bearing cap bolt.: 12 - 14 Nm (120 - 140 kg.cm, 9 - 10 lb.ft)
Page 75 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 69: Bearing Cap Installation Courtesy of HYUNDAI MOTOR CO. 6. Using the special tool, camshaft oil seal installer (09221-21000), press fit the camshaft oil seal. Be sure to apply engine oil to the oil seal lip. Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is fully seated.
Page 76 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 70: Installing Camshaft Oil Seal Courtesy of HYUNDAI MOTOR CO. 7. Install the camshaft sprocket bolts to the specified torque. Tightening torque Camshaft sprocket bolt: 80 - 100 Nm (800 - 1000 kg.cm, 59 - 74 lb.ft) viernes, 19 de febrero de 2021 07:12:58 a.
Page 77 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 71: Installing Camshaft Sprocket Bolts Courtesy of HYUNDAI MOTOR CO. 8. Align the camshaft sprocket and crankshaft sprocket timing marks. Place the piston in the No.1 cylinder to top dead center on the compression stroke.
Page 78 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 72: Identifying Cylinder Head Cover Courtesy of HYUNDAI MOTOR CO. 10. Install the spark plug cables, ignition coil assembly and cylinder head center cover. viernes, 19 de febrero de 2021 07:12:58 a. m.
Page 79 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 73: Identifying Spark Plug Cables, Ignition Coil Assembly & Cylinder Head Center Cover Courtesy of HYUNDAI MOTOR CO. 11. Install the timing belt and then tighten the timing belt tensioner pulley.
Page 80 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 74: Crank Shaft Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Remove the timing belt, front case, flywheel, cylinder head assembly and oil pan. 2. Remove the rear plate and the rear oil seal.
Page 81 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 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. 2. Inspect the crankshaft journal for taper and out - of - round.
Page 82 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 75: Checking Clearance Between Sensor Wheel & Crank Position Sensor Courtesy of HYUNDAI MOTOR CO. NOTE: 1. Measure the depth of the top of sensor wheel tooth and the cylinder block mounting block.
Page 83 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 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 correct.
Page 84 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 76: Identifying Arrow Mark Indicating Front Of Engine Courtesy of HYUNDAI MOTOR CO. 4. 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.
Page 85 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 77: Installing Oil Seal In Crankshaft Rear Oil Seal Case Courtesy of HYUNDAI MOTOR CO. 6. Install the rear plate and tighten the bolts. 7. Install the connecting rod caps.
Page 86 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 78: Fly Wheel Components Courtesy of HYUNDAI MOTOR CO. M/T: Manual Transmission Vehicles A/T: Automatic Transmission Vehicles DISASSEMBLY 1. Remove the Transmission and clutch. 2. Remove the flywheel.
Page 87 1. Install the flywheel assembly and tighten the bolts to the specified torque. Tightening torque Flywheel bolt: 120-130Nm (1200-1300kg.cm, 89-96lb.ft) PISTON COMPONENTS Fig. 79: Piston Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY viernes, 19 de febrero de 2021 07:12:58 a. m. Page 87 © 2011 Mitchell Repair Information Company, LLC.
Page 88 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent CONNECTING ROD CAP CAUTION: Keep the bearings in order with their corresponding connecting rods (according to cylinder numbers) for proper reassembly. 1. Remove the connecting rod cap bolts, then remove the caps and the big end lower bearing.
Page 89 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 80: Identifying Connecting Rod Notches Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY AND REASSEMBLY OF THE PISTON PIN 1. Using the special tools (09234-33001) and (09234-33002), disassemble and reassemble the piston and connecting rod.
Page 90 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 82: Placing Piston In Support Fixture Courtesy of HYUNDAI MOTOR CO. 5. To install a new pin, the proper fork inserts must be in place to support the rod. 6. Position the rod inside the piston. Insert the proper pin guide through one side of the piston and through the rod.
Page 91 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 83: Installing Piston Pin Courtesy of HYUNDAI MOTOR CO. 7. Insert the installer tool through the hole in the arch of the support fixture and use an hydraulic press to force the piston pin through the rod little end.
Page 92 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 84: Inserting Piston Pin Through Rod Little End Courtesy of HYUNDAI MOTOR CO. INSPECTION PISTONS AND PISTON PINS 1. Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective.
Page 93: Piston Rings
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent PISTON RINGS 1. Measure the piston ring side clearance. If the measured value exceeds the service limit, insert a new ring in the ring groove to measure the side clearance. If the clearance still exceeds the service limit, replace the piston and rings together.
Page 94 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 0.50mm (0.020 in.) O.S 50 0.75mm (0.030 in.) O.S 75 1.00mm (0.039 in.) O.S 100 NOTE: The mark can be found on the upper side of the ring next to the end.
Page 95 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 85: Installing Piston Rings Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:58 a. m. Page 95 © 2011 Mitchell Repair Information Company, LLC.
Page 96: Connecting Rods
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent CONNECTING RODS 1. When the connecting rod cap is installed, make sure that the cylinder numbers, marked on rod end cap at disassembly, match. When a new connecting rod is installed, make sure that the notches holding the bearing in place are on the same side.
Page 97 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Courtesy of HYUNDAI MOTOR CO. REASSEMBLY 1. Install the spacer. Fig. 87: Installing Spacer Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 98 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 88: Positioning Spacer Courtesy of HYUNDAI MOTOR CO. 2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with a finger on the portion to be inserted into the groove (as illustrated).
Page 99 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 89: Installing Piston Lower Side Rail Courtesy of HYUNDAI MOTOR CO. 4. Apply engine oil around the piston and piston grooves. 5. Using a piston ring expander, install the No.2 piston ring.
Page 100 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 90: Locating No. 1 & No. 2 Piston Rings Courtesy of HYUNDAI MOTOR CO. 7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions.
Page 101 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 91: Positioning Piston Ring End Gaps Courtesy of HYUNDAI MOTOR CO. 9. Install the upper main bearings in the cylinder block. 10. Install the lower main bearings in the main bearing caps.
Page 102: Cooling System
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent times. 14. Check the connecting rod side clearance. Connecting rod side clearance Standard: 0.10-0.25 mm (0.0039-0.0098 in.) Limit: 0.4 mm (0.0157 in.) 15. Install the oil screen.
Page 103 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 92: Engine Coolant Hose/Pipes Courtesy of HYUNDAI MOTOR CO. COMPONENTS viernes, 19 de febrero de 2021 07:12:59 a. m. Page 103 © 2011 Mitchell Repair Information Company, LLC.
Page 104 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 93: Cooling System Components Courtesy of HYUNDAI MOTOR CO. INSPECTION Check the coolant pipe and hoses for cracks, damage, or restrictions. Replace if necessary. REASSEMBLY 1. Fit on O-ring in the groove provided at the coolant inlet pipe end, wet the O-ring with coolant and insert the coolant inlet pipe.
Page 105: Engine Coolant Pump
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 4. Do not reuse the O-ring. Replace it with a new part. Fig. 94: Identifying Coolant Pump & Inlet Pipe Courtesy of HYUNDAI MOTOR CO. ENGINE COOLANT PUMP COMPONENTS viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 106 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 95: Engine Coolant Pump Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Drain the coolant and disconnect the coolant inlet pipe connection hose from the coolant pump.
Page 107 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent viernes, 19 de febrero de 2021 07:12:59 a. m. Page 107 © 2011 Mitchell Repair Information Company, LLC.
Page 108 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 96: Identifying Engine Coolant Pump Courtesy of HYUNDAI MOTOR CO. REASSEMBLY 1. Clean the gasket surfaces of the coolant pump body and the cylinder block. 2. Install a new coolant pump gasket to the coolant pump and tighten the bolts to the specified torque.
Page 109 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent RADIATOR COMPONENTS Fig. 98: Radiator Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Disconnect the radiator fan motor connector. viernes, 19 de febrero de 2021 07:12:59 a. m. Page 109...
Page 110 2. Set the temperature of the heater control to the hot position. Fig. 99: Identifying Heater Control Knob Courtesy of HYUNDAI MOTOR CO. 3. Loosen the radiator drain plug to drain coolant. 4. Disconnect the upper and lower hose and overflow tube.
Page 111: Radiator Fan Motor
1. Check that the radiator fan rotates when the battery voltage is applied to the terminals. Fig. 100: Checking Radiator Fan Operation Courtesy of HYUNDAI MOTOR CO. 2. Check that abnormal noises are not produced while the motor is turning.
Page 112: Radiator Cap
4. Check that there are no leaks from the radiator, hoses or connections. RADIATOR CAP COMPONENTS Fig. 101: Radiator Cap Components Courtesy of HYUNDAI MOTOR CO. INSPECTION 1. Check the radiator cap for damage, cracks and deterioration. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 113 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 102: Checking Radiator Cap For Deterioration Courtesy of HYUNDAI MOTOR CO. 2. Attach a radiator cap tester to the radiator. 3. Pump the tester until the pointer stabilizes.
Page 114 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 103: Attaching Radiator Cap Tester To Radiator Cap Courtesy of HYUNDAI MOTOR CO. THERMOSTAT COMPONENTS viernes, 19 de febrero de 2021 07:12:59 a. m. Page 114...
Page 115: Disassembly And Inspection
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 104: Thermostat Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY AND INSPECTION 1. Drain the coolant so its level is below thermostat. 2. Remove the inlet fitting and gasket.
Page 116: Coolant Temperature Sensor
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 105: Checking Thermostat Valve Opening Temperature Courtesy of HYUNDAI MOTOR CO. COOLANT TEMPERATURE SENSOR 1. Heat the sensor by submerging it in hot engine coolant. 2. Check that the resistance is within the specified range.
Page 117: Lubrication System
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Tightening torque Coolant temperature sensor: 20 - 40 Nm (200 - 400 kg.cm, 15 - 30 lb.ft) LUBRICATION SYSTEM OIL PUMP COMPONENTS viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 118 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 106: Oil Pump Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Remove the timing belt. 2. Remove all the oil pan bolts. 3. Remove the oil pan.
Page 119: Front Case
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 107: Removing Front Case Assembly Courtesy of HYUNDAI MOTOR CO. 6. Remove the oil pump cover. 7. Remove the inner and outer gears from the front case. The matching marks on the inner and outer gears indicate the direction of installation.
Page 120: Oil Pump Gears
Inner gear: 0.04 - 0.085 mm (0.0016 - 0.0033 in.) Fig. 108: Measuring Clearance Between Outer Gear & Front Case Courtesy of HYUNDAI MOTOR CO. 3. Check the tip clearance on the pump rotor. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 121 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 109: Checking Tip Clearance On Pump Rotor Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:59 a. m. Page 121 © 2011 Mitchell Repair Information Company, LLC.
Page 122 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 110: Checking Side Clearance On Pump Rotor Courtesy of HYUNDAI MOTOR CO. Fig. 111: Checking Body Clearance Courtesy of HYUNDAI MOTOR CO. RELIEF VALVE AND SPRING 1.
Page 123: Oil Pressure Switch
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Standard value Free height: 46.6 mm (1.8346 in.) Load: 6.1 kg/40.1 mm (13.42 lb/1.578 in.) OIL PRESSURE SWITCH 1. Use an ohmmeter to check the continuity between the terminal and the body. If there is no continuity, replace the oil pressure switch.
Page 124 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 112: Checking Continuity Between Oil Pressure Switch Terminal & Body Courtesy of HYUNDAI MOTOR CO. 2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch.
Page 125 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 113: Checking Continuity Between Oil Pressure Switch Terminal & Body - Fine Wire Pushed Courtesy of HYUNDAI MOTOR CO. 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.
Page 126 Relief valve plug: 40-50 Nm (400-500 kg.cm, 30-37 lb.ft) [Body clearance] Fig. 114: Inspecting Oil Pump Body Clearance Courtesy of HYUNDAI MOTOR CO. FRONT CASE 1. Install the front case assembly with a new gasket, and tighten the bolts to the specified torque.
Page 127 C: 60 mm (2.36 in.) D: 22 mm (0.89 in.) Fig. 115: Locating Front Case Assembly Bolts Courtesy of HYUNDAI MOTOR CO. OIL SEAL 1. Using the special tool, Crankshaft oil seal guide (09214 - 21100), install the oil seal.
Page 128 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 116: Installing Oil Seal Using Crankshaft Oil Seal Guide Courtesy of HYUNDAI MOTOR CO. 2. Using the special tool, Crankshaft front oil seal installer (09214-21000), install the oil seal. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 129 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 117: Installing Oil Seal Using Crankshaft Front Oil Seal Installer Courtesy of HYUNDAI MOTOR CO. 3. Install the oil screen. 4. Clean both gasket surfaces of the oil pan and the cylinder block.
Page 130: Intake And Exhaust System
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 118: Applying Sealant Into Groove Of Oil Pan Flange Courtesy of HYUNDAI MOTOR CO. 6. Install the oil pan and tighten the bolts to the specified torque. Tightening torque Oil pan bolt: 10-12 Nm (100 - 120 kg.cm, 7-9 lb.ft)
Page 131 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent COMPONENTS Fig. 119: Exhaust Manifold Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Remove the exhaust manifold heat protector. 2. Remove the exhaust manifold assembly from the cylinder head.
Page 132: Intake Manifold
CAUTION: Replace the exhaust manifold gasket and lock nut when reassembling. INTAKE MANIFOLD COMPONENTS Fig. 120: Intake Manifold Components Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:59 a. m. Page 132 © 2011 Mitchell Repair Information Company, LLC.
Page 133 REMOVAL 1. Remove the engine cover. Fig. 121: Removing Engine Cover Courtesy of HYUNDAI MOTOR CO. 2. Remove the intake air hose connected to the throttle body. 3. Remove the accelerator cable. 4. Remove the P.C.V. hose and brake booster vacuum hoses.
Page 134 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 122: Disconnecting Vacuum Hose Connections Courtesy of HYUNDAI MOTOR CO. 6. Disconnect the high pressure fuel hose connection after relieving pressure in the fuel rail to prevent fuel from spilling.
Page 135: Installation
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 123: Removing Delivery Pipe With Fuel Injectors Courtesy of HYUNDAI MOTOR CO. INSPECTION INTAKE MANIFOLD Check the parts for damage or cracking. AIR HOSE Check for damage or cracking of any part.
Page 136 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 124: Installing Delivery Pipe With Fuel Injectors Courtesy of HYUNDAI MOTOR CO. 2. Install the delivery pipe with the fuel injectors. 3. Connect the fuel injector harness connector.
Page 137 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 125: Muffler Components Courtesy of HYUNDAI MOTOR CO. REMOVAL MAIN MUFFLER CAUTION: Before removing or inspecting the exhaust system, ensure that the exhaust system has cooled sufficiently.
Page 138 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 126: Disconnecting Main Muffler From Center Muffler Courtesy of HYUNDAI MOTOR CO. 2. Remove the rubber hangers and remove the main muffler. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 139 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 127: Removing Rubber Hangers & Removing Main Muffler Courtesy of HYUNDAI MOTOR CO. CENTER MUFFLER 1. Remove the center muffler assembly from the main muffler and front exhaust pipe.
Page 140: Front Exhaust Pipe
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 128: Removing Center Muffler Assembly From Main Muffler Courtesy of HYUNDAI MOTOR CO. 2. Remove the rubber hanger, then remove the center muffler. FRONT EXHAUST PIPE 1.
Page 141 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 129: Removing Front Exhaust Pipe & Center Muffler Bolt Courtesy of HYUNDAI MOTOR CO. INSTALLATION 1. Temporarily install the front exhaust pipe, the center exhaust pipe, and the main muffler, in that order.
Page 142 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 130: Air Cleaner Components Courtesy of HYUNDAI MOTOR CO. REMOVAL 1. Remove the air duct connected to the air cleaner. 2. Disconnect the intake air temperature sensor harness.
Page 143 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 131: Identifying Air Cleaner Courtesy of HYUNDAI MOTOR CO. INSPECTION 1. Check the air cleaner body, cover, or filter for distortion, corrosion or damage. 2. Check the air duct for damage.
Page 144 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 132: Checking Resonator For Distortion Or Damage Courtesy of HYUNDAI MOTOR CO. 4. Check the air cleaner filter for restriction, contamination or damage. If the filter is slightly restricted, remove the dust and other contaminants by blowing compressed air from the upper side through the filter.
Page 145: Cylinder Head Assembly
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 133: Cleaning Air Filter Courtesy of HYUNDAI MOTOR CO. 5. Check the air cleaner housing for restrictions, contamination or damage. INSTALLATION Install the air cleaner assembly following the reverse order of removal.
Page 146 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 134: Cylinder Head Components viernes, 19 de febrero de 2021 07:12:59 a. m. Page 146 © 2011 Mitchell Repair Information Company, LLC.
Page 147 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Courtesy of HYUNDAI MOTOR CO. VALVES COMPONENTS Fig. 135: Valves & Components Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:12:59 a. m. Page 147...
Page 148 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent DISASSEMBLY 1. Using a special tool (09221-32001), remove the cylinder head bolts in the order shown in the illustration. viernes, 19 de febrero de 2021 07:12:59 a. m.
Page 149 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 136: Removal Order Of Cylinder Head Bolts Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 149 © 2011 Mitchell Repair Information Company, LLC.
Page 150 Arrange these parts so that they can be reinstalled in their original positions. Fig. 137: Removing Valve Retainer Lock Courtesy of HYUNDAI MOTOR CO. 3. Remove the valve stem seals with pliers. NOTE: Do not reuse the valve stem seals.
Page 151 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 138: Removing Valve Stem Seals Courtesy of HYUNDAI MOTOR CO. INSPECTION CYLINDER HEAD 1. Check the cylinder head for cracks, damage and coolant leakage. If cracked, replace the cylinder head.
Page 152 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 139: Checking Cylinder Head Flatness Courtesy of HYUNDAI MOTOR CO. 3. Check the cylinder head surface for flatness in the direction as shown in the illustration. If flatness exceeds the service limit in any direction, either replace the cylinder head or machine the cylinder head matching surface lightly.
Page 153 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 140: Cleaning Valve Courtesy of HYUNDAI MOTOR CO. 2. Check each valve for wear, damage and distortion of the head and the stem at B position. Replace, if necessary. If stem end, A, is hollowed out or worn, resurface as necessary. This correction must be limited to a minimum.
Page 154 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 141: Checking Valve Head For Distortion Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 154 © 2011 Mitchell Repair Information Company, LLC.
Page 155: Valve Springs
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent VALVE SPRINGS 1. Check the free height of each valve spring. If they exceed the service limit, replace the springs. 2. Using a square, test the squareness of each spring. If a spring is excessively out-of-square, replace it.
Page 156: Valve Guides
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 142: Identifying Valve Spring Free Height & Squareness Courtesy of HYUNDAI MOTOR CO. VALVE GUIDES viernes, 19 de febrero de 2021 07:13:00 a. m. Page 156...
Page 157 Intake: 0.1mm(0.0040 in) Exhaust: 0.15mm(0.0059 in.) Fig. 143: Checking Valve Stem-To-Guide Clearance Courtesy of HYUNDAI MOTOR CO. RECONDITIONING VALVE SEAT Check the valve seat for overheating and unequal contact with the valve face. Recondition or replace the seat if viernes, 19 de febrero de 2021 07:13:00 a. m.
Page 158 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent necessary. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it and then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
Page 159 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 144: Reconditioning Valve Seat Courtesy of HYUNDAI MOTOR CO. REPLACING THE VALVE SEAT RING 1. Cut away the inner face of the valve seat to reduce the wall thickness.
Page 160: Replacing Valve Guide
2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent VALVE SEAT INSERT OVERSIZE Fig. 146: Valve Seat Insert Overissues Courtesy of HYUNDAI MOTOR CO. REPLACING VALVE GUIDE 1. Using the special tool (09221-22000 A/B), withdraw the old valve guide toward the bottom of cylinder head.
Page 161 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 147: Replacing Valve Guide Courtesy of HYUNDAI MOTOR CO. 3. Using the special tool (09221-22000 A/B), press-fit the valve guide. The valve guide must be press-fitted from the upper side of the cylinder head.
Page 162 5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary. VALVE GUIDE OVERISSUES Fig. 148: Valve Guide Oversize Table Courtesy of HYUNDAI MOTOR CO. REASSEMBLY NOTE: 1. Clean each part before assembly.
Page 163 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 149: Inserting Valve Into Valve Guide Courtesy of HYUNDAI MOTOR CO. 3. Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer.
Page 164 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 150: Installing Retainer Courtesy of HYUNDAI MOTOR CO. 4. Using the special tool (09222-28000, 09222-28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
Page 165 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 151: Installing Retainer Locks Courtesy of HYUNDAI MOTOR CO. NOTE: When the spring is compressed, Check that the valve stem seal is not pressed against the bottom of the retainer.
Page 166 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 152: Tightening Cylinder Head Bolts viernes, 19 de febrero de 2021 07:13:00 a. m. Page 166 © 2011 Mitchell Repair Information Company, LLC.
Page 167: Timing System
2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Courtesy of HYUNDAI MOTOR CO. Cylinder head bolt: 35 Nm (26 lb.ft) + 90° + Release all bolt + 35 Nm (26 lb.ft) + 90° TIMING SYSTEM...
Page 168 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent 5. Remove the timing belt cover. Fig. 154: Removing Timing Belt Cover Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 168 © 2011 Mitchell Repair Information Company, LLC.
Page 169 (on the front of the engine) to make sure that the belt is reinstalled in the same direction as before. Fig. 155: Referencing Timing Belt Direction Courtesy of HYUNDAI MOTOR CO. 10. Remove the crankshaft sprocket bolts. Remove the crankshaft sprocket and flange. 11. Remove the timing belt tensioner.
Page 170 3. Replace the pulley if there is a grease leak from its bearing. Fig. 156: Inspecting Tensioner Pulley & Idler Pulley Movement Courtesy of HYUNDAI MOTOR CO. TIMING BELT 1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper.
Page 171 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 157: Precautions For Timing Belt Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 171 © 2011 Mitchell Repair Information Company, LLC.
Page 172 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 158: Timing Belt Flaw Conditions (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 172 © 2011 Mitchell Repair Information Company, LLC.
Page 173 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 159: Timing Belt Flaw Conditions (2 Of 2) Courtesy of HYUNDAI MOTOR CO. REASSEMBLY 1. Install the flange and crankshaft sprocket as shown. Pay close attention to their mounting directions.
Page 174 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 160: Installing Flange & Crankshaft Sprocket Courtesy of HYUNDAI MOTOR CO. 2. Install the camshaft sprocket and tighten the bolt to the specified torque. Tightening torque Camshaft sprocket bolt: 80-100Nm (800-1000kg.cm, 59-74lb.ft)
Page 175 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 161: Identifying Camshaft Sprockets Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 175 © 2011 Mitchell Repair Information Company, LLC.
Page 176 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 162: Installing Camshaft Sprockets Courtesy of HYUNDAI MOTOR CO. 5. To install the timing belt tensioner, first mount the tensioner, spring, and spacer. Temporarily tighten the bolts. Next, temporarily tighten the tensioner long hole side washer and bolts. Install the bottom end of the spring against the front case as shown in the illustration.
Page 177 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 163: Installing Timing Belt Tensioner Courtesy of HYUNDAI MOTOR CO. 6. Secure the tensioner, positioned towards the water pump. 7. Install the timing belt on the crankshaft sprocket.
Page 178 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 164: Tightening Tensioner Bolts Courtesy of HYUNDAI MOTOR CO. 9. Tighten the tensioner bolts. 10. Give the crankshaft one turn in its operating direction (clock-wise) and realign the crankshaft sprocket timing mark with the top dead center position.
Page 179 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 165: Checking Timing Belt Tension Courtesy of HYUNDAI MOTOR CO. 12. Install the timing belt cover. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 179...
Page 180 2002 Hyundai Accent GL 2002 ENGINE Engine Mechanical System (DOHC 1.6L) - Accent Fig. 166: Installing Timing Belt Cover Courtesy of HYUNDAI MOTOR CO. Tightening torque viernes, 19 de febrero de 2021 07:13:00 a. m. Page 180 © 2011 Mitchell Repair Information Company, LLC.
Page 181 15. Install the water pump pulley. 16. Install V-belt and adjust the belt tension. Fig. 167: Installing V-Belt Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:13:00 a. m. Page 181 © 2011 Mitchell Repair Information Company, LLC.

Hyundai Accent GL 2002 Manual

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