Page 1 2004 Hyundai Accent 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 2004 ENGINES 1.6L 4-Cylinder - Accent GENERAL SPECIFICATIONS General Engine Specifications Description Specification Limit General Type In-line, Double Over Head Camshaft Number of cylinders Bore 76.5 mm (3.0118 in)
Page 2 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Guide hole 0.05 mm (0.002 in.) O.S. 11.05 ~ 11.068 mm (0.435 ~ 0.4357 in.) 0.25 mm (0.010 in.) O.S. 11.25 ~ 11.268 mm (0.443 ~ 0.4436 in.) 0.50 mm (0.020 in.) O.S.
Page 3 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Seat angle 45° 0.3, 0.6 mm (0.012, 0.024 in.) Oversize oversize Valve spring Free length 44.00 mm (1.7323 in.) 21.6kg/35 mm (47.6lb/1.3780 in.) Load 45.1 kg/27.2 mm (99.4lb/1.071 in.) Squareness 1.5° or less Cylinder block 76.50 ~ 76.53 mm (3.0118 ~...
Page 4 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Pin O.D. 45 mm (1.77 in.) Journal O.D. 50 mm (1.97 in.) Berid 0.03 mm (0.0012 in.) or less Out- of- round, taper of journal 0.005 mm (0.0002 in.) or less and pin 0.05 - 0.175 mm (0.0019 - 0.0068...
Page 5 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Coolant Quantity 6.5 liter Radiator Type Pressurized corrugated fin type Radiator cap 81.4 ~ 108 kpa (11.8 ~ 15.6 psi., Main valve opening pressure 0.83 ~ 1.1 kg/cm -6.86 kpa (-1.00 psi, -0.07 kg/cm...
Page 6 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Crankshaft Pulley Bolt 103-111 (140-150) Cylinder Head Bolts Step 1 22 (30) Step 2 Tighten An Additional 90 Degrees Step 3 Release All Bolts Step 4 22 (30) Step 5 Tighten An Additional...
Page 7 Timing Belt Cover Bolt 71-88 (8-10) Tighten cylinder head bolts in sequence. See Fig. 1. Fig. 1: Identifying Cylinder Head Tightening Sequence Courtesy of HYUNDAI MOTOR CO. SERVICE STANDARD viernes, 19 de febrero de 2021 07:44:31 a. m. Page 7...
Page 8 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 2: Identifying Engine Coolant & Mixture Courtesy of HYUNDAI MOTOR CO. CHECKING ENGINE OIL 1. Position the vehicle on a level surface. 2. Warm up the engine. NOTE: If a vehicle has been out of service for a prolonged period of time, warm up the engine for approximately 20 minutes.
Page 9 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 4: Locating Engine Oil Drain Plug Courtesy of HYUNDAI MOTOR CO. 4. Install and tighten the drain plug to the specified torque. Tightening torque Drain plug: 40 ~ 45 Nm (400 ~ 450 kg.cm, 30 ~ 33 lb.ft) 5.
Page 10 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 11 1. Use a filter wrench to remove the oil filter. Fig. 6: Locating Engine Oil Filter Courtesy of HYUNDAI MOTOR CO. 2. Before installing the new oil filter on the engine, apply clean engine oil to the surface of the rubber gasket.
Page 12 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 7: Removing Engine Oil Filter & Applying Engine Oil To New 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 13 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 8: Identifying 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: 1. Satisfy the requirements of the API classification.
Page 14 4. If there is leakage, repair or replace with the appropriate part. Fig. 9: Testing Coolant System for Leak Courtesy of HYUNDAI MOTOR CO. RADIATOR CAP PRESSURE TEST 1. Remove the radiator cap, wet its seal with engine coolant, then install it on the tester.
Page 15 Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an incorrect reading. Fig. 10: Pressure Testing Radiator Cap Courtesy of HYUNDAI MOTOR CO. SPECIFIC GRAVITY TEST viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 16 1. Measure the specific gravity of the coolant with a hydrometer. Fig. 11: Using Hydrometer To Test Coolant Gravity Courtesy of HYUNDAI MOTOR CO. 2. Measure the coolant temperature and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference.
Page 17 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 12: Coolant Concentration & Specific Gravity Specifications 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 18 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 14: Locating Coolant Drain Plug Courtesy of HYUNDAI MOTOR CO. 4. Tighten the radiator drain plug securely. 5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the MAX mark with water, then up to the MAX mark with antifreeze.
Page 19 4. Disconnect the fuel pump connector. 5. Turn off engine and disconnect the spark plug cables. Fig. 15: Removing Spark Plug Cable From Cylinder Head Courtesy of HYUNDAI MOTOR CO. 6. Remove the spark plugs. 7. Disconnect the I.G. connector.
Page 20 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 16: Inserting Compression Gauge Into Spark Plug Hole Courtesy of HYUNDAI MOTOR CO. 10. Depress the accelerator pedal to open the throttle fully. 11. Crank the engine and read the gauge.
Page 21 2. Lift the vehicle by using of jack. Fig. 17: Lifting Vehicle With Jack Courtesy of HYUNDAI MOTOR CO. 3. Remove the engine support bracket. (14mm bolt and 2nuts, 17mm bolt) viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 22 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 18: Removing Engine Support Bracket Courtesy of HYUNDAI MOTOR CO. 4. Remove the drive belts and the water pump pulley. (10 mm 4 bolts) viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 23 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 19: Removing Water Pump Pulley Courtesy of HYUNDAI MOTOR CO. 5. Remove the timing belt upper cover. (10 mm 4 bolts) viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 24 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 20: Removing Timing Belt Upper Cover Courtesy of HYUNDAI MOTOR CO. 6. Remove the crankshaft pulley. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 24 © 2011 Mitchell Repair Information Company, LLC.
Page 25 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 21: Removing Crankshaft Pulley Courtesy of HYUNDAI MOTOR CO. 7. Remove the timing belt lower cover. 8. Place the piston of No. 1 cylinder to TDC of the compression stroke by rotating the crankshaft clockwise.
Page 26 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 22: Loosening Tensioner Bolt Courtesy of HYUNDAI MOTOR CO. 10. Rotate the crankshaft clockwise as many as 2 teeth of camshaft sprocket. 11. Check that the teeth of the sprocket and belt coincide with each other.
Page 27 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 23: Checking Timing Belt Tension Courtesy of HYUNDAI MOTOR CO. 14. Rotate the crankshaft pulley two turns clockwise so that the timing belt positions on the pulleys. 15. Install the timing belt lower cover.
Page 28 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 24: Checking Drive Belt Alignment Courtesy of HYUNDAI MOTOR CO. CAUTION: 1. When installing the V-ribbed belt, check that the V-ribs are properly aligned. 2. If noise or slippage is detected, check the belt for wear, damage, or breakage on the pulley contact surface, and check the pulley for scoring.
Page 29 "Used" in Fig. 25. 4. Refer to Fig. 25 for periodic inspections. Fig. 26: Locating Drive Belt 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 30 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 27: Measuring Drive Belt Tension 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 31 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 28: Identifying 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. If the belt is too tight, the engine coolant pump bearing or the alternator can get damaged.
Page 32 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. 29: Adjusting Alternator Belt Courtesy of HYUNDAI MOTOR CO. ENGINE AND TRANSAXLE ASSEMBLY REMOVAL WARNING: Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct position on the engine.
Page 33 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Make sure the vehicle will not roll off stands and fall while you are working under it. CAUTION: Use fender covers to avoid damaging painted surface. 1. Remove the battery. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 34 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 30: Removing Battery Courtesy of HYUNDAI MOTOR CO. 2. Detach the air cleaner. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 34 © 2011 Mitchell Repair Information Company, LLC.
Page 35 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 31: Removing Air Cleaner Courtesy of HYUNDAI MOTOR CO. 3. Disconnect the connectors for engine harness. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 35 © 2011 Mitchell Repair Information Company, LLC.
Page 36 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 32: Disconnecting Engine Harness Connectors (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 36 © 2011 Mitchell Repair Information Company, LLC.
Page 37 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 33: Disconnecting Engine Harness Connectors (1 Of 2) Courtesy of HYUNDAI MOTOR CO. 4. Disconnect the engine ground. 5. Disconnect the connectors for the alternator harness and the oil pressure gauge wiring.
Page 38 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 34: Disconnecting Connectors For Alternator Harness & Oil Pressure Gauge Courtesy of HYUNDAI MOTOR CO. 6. Disconnect the brake booster vacuum hose. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 39 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 35: Disconnecting Brake Booster Vacuum Hose Courtesy of HYUNDAI MOTOR CO. 7. Remove the main fuel line, the return and vapor hoses from the engine side. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 40 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 36: Removing Main Fuel Line, Return & Vapor Hoses From Engine Side (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 40...
Page 41 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 37: Removing Main Fuel Line, Return & Vapor Hoses From Engine Side (2 Of 2) Courtesy of HYUNDAI MOTOR CO. 8. Disconnect the transaxle oil cooler hoses. (A/T) viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 42 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 38: Disconnecting Transaxle Oil Cooler Hoses (A/T) 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 43 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 39: Locating Engine Coolant Drain Plug Courtesy of HYUNDAI MOTOR CO. 10. Disconnect the radiator upper and lower hoses on the engine side, then remove the radiator assembly. 11. Disconnect the heater hoses (inlet and outlet) on the engine side.
Page 44 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 40: Disconnecting Heater Hoses (Inlet & Outlet) On Engine Side Courtesy of HYUNDAI MOTOR CO. 12. Disconnect the accelerator cable at the engine side. 13. For vehicles with automatic transmission, remove the control cable from the transmission.
Page 45 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:31 a. m. Page 45 © 2011 Mitchell Repair Information Company, LLC.
Page 46 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 41: Removing Control Cable From Transmission (A/T) Courtesy of HYUNDAI MOTOR CO. 14. Disconnect the inhibitor switch and solenoid valve connector. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 47 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:31 a. m. Page 47 © 2011 Mitchell Repair Information Company, LLC.
Page 48 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 42: Disconnect Inhibitor Switch & Solenoid Valve Connector Courtesy of HYUNDAI MOTOR CO. 15. Disconnect the vehicle speed sensor connector. Fig. 43: Disconnecting Vehicle Speed Sensor Connector Courtesy of HYUNDAI MOTOR CO.
Page 49 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 44: Disconnecting Clutch Tube Courtesy of HYUNDAI MOTOR CO. 17. Disconnect the air conditioner compressor from the mounting bracket. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 49...
Page 50 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 45: Disconnecting Air Conditioner Compressor From Mounting Bracket Courtesy of HYUNDAI MOTOR CO. 18. Jack up the vehicle. 19. Disconnect the start motor connector and ground. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 51 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 46: Disconnecting Starter Motor Connector & Ground (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 51 © 2011 Mitchell Repair Information Company, LLC.
Page 52 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 47: Disconnecting Starter Motor Connector & Ground (2 Of 2) Courtesy of HYUNDAI MOTOR CO. 20. Disconnect the front exhaust pipe from the manifold. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 53 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 48: Disconnecting Front Exhaust Pipe From Manifold Courtesy of HYUNDAI MOTOR CO. NOTE: Use wire to suspend the exhaust pipe from the bottom of the vehicle. 21. Remove the knuckle form the front damper.
Page 54 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 49: Removing Knuckle Form Front Damper Courtesy of HYUNDAI MOTOR CO. 22. Remove the caliper from the knuckle and hang the caliper from the front damper with wire. viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 55 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 50: Removing Caliper From Knuckle & Hang Caliper From Front Damper With Wire Courtesy of HYUNDAI MOTOR CO. 23. Remove the wheel speed sensor form the knuckle. (with ABS) viernes, 19 de febrero de 2021 07:44:31 a. m.
Page 56 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 51: Removing Wheel Speed Sensor Form Knuckle (With ABS) Courtesy of HYUNDAI MOTOR CO. 24. Attach a chains or cables to the engine. Use an engine hoist or a chain hoist to slightly raise the engine (enough to support the engine's weight while processing with the following steps).
Page 57 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 52: Attaching Chains Or Cables To Remove Engine Courtesy of HYUNDAI MOTOR CO. 25. Remove the steering joint bolt. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 57...
Page 58 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 53: Removing Steering Joint Bolt Courtesy of HYUNDAI MOTOR CO. 26. Remove the engine mounting bracket from the engine. viernes, 19 de febrero de 2021 07:44:31 a. m. Page 58...
Page 59 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 54: Removing Engine Mounting Bracket From Engine Courtesy of HYUNDAI MOTOR CO. 27. 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 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 55: Removing Caps From Inside Of Right Fender Shield Courtesy of HYUNDAI MOTOR CO. 29. Remove the sub frame fixing bolts and nuts. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 61 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 56: Removing Sub Frame Fixing Bolts & Nuts Courtesy of HYUNDAI MOTOR CO. 30. While directing the transmission side downward, lift the engine and transmission assembly down and out of the vehicles.
Page 62 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 57: Identifying Special Tools (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 62 © 2011 Mitchell Repair Information Company, LLC.
Page 63 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 58: Identifying Special Tools (2 Of 2) Courtesy of HYUNDAI MOTOR CO. TROUBLESHOOTING viernes, 19 de febrero de 2021 07:44:32 a. m. Page 63 © 2011 Mitchell Repair Information Company, LLC.
Page 64 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 59: Trouble Shooting Table (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 64 © 2011 Mitchell Repair Information Company, LLC.
Page 65 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 60: Trouble Shooting Table (2 Of 2) Courtesy of HYUNDAI MOTOR CO. TIMING SYSTEM TIMING BELT COMPONENTS viernes, 19 de febrero de 2021 07:44:32 a. m. Page 65 © 2011 Mitchell Repair Information Company, LLC.
Page 66 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 61: Identifying Timing Belt Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Lift the vehicle by using of jack. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 66...
Page 67 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 62: Lifting Vehicle With Jack Courtesy of HYUNDAI MOTOR CO. 2. Remove the engine support bracket. (14 mm bolt and 2 nuts, 17 mm bolt) viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 68 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 63: Removing Engine Support Bracket Courtesy of HYUNDAI MOTOR CO. 3. Remove the power steering belt. 4. Remove the air conditioning compressor belt. 5. Remove the alternator belt. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 69 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:32 a. m. Page 69 © 2011 Mitchell Repair Information Company, LLC.
Page 70 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 64: Locating Alternator Adjuster Bolt Courtesy of HYUNDAI MOTOR CO. 6. Remove the coolant pump pulley. Fig. 65: Removing Coolant Pump Pulley Courtesy of HYUNDAI MOTOR CO. 7. Remove the crankshaft pulley.
Page 71 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 66: Removing Crankshaft Pulley Courtesy of HYUNDAI MOTOR CO. 8. Remove the timing belt cover. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 71 © 2011 Mitchell Repair Information Company, LLC.
Page 72 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 67: Removing Timing Belt Cover Courtesy of HYUNDAI MOTOR CO. 9. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 73 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 68: Loosening Timing Belt Tensioner Courtesy of HYUNDAI MOTOR CO. 10. Remove the timing belt. NOTE: If the timing belt is reused, mark with an arrow to indicate direction of rotation (on the front of the engine) to make sure that the belt is reinstalled in the same direction as before.
Page 74 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 69: Marking Timing Belt For Installation Courtesy of HYUNDAI MOTOR CO. 11. Remove the camshaft from the camshaft sprocket. 12. Remove the crankshaft sprocket and flange. 13. Remove the timing belt idler.
Page 75 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 70: Removing Timing Belt Tensioner Courtesy of HYUNDAI MOTOR CO. INSPECTION SPROCKETS TENSIONER PULLEY, AND IDLER PULLEY viernes, 19 de febrero de 2021 07:44:32 a. m. Page 75 © 2011 Mitchell Repair Information Company, LLC.
Page 76 Replace as necessary. 3. Replace the pulley if there is a grease leak from its bearing. Fig. 71: Inspecting Pulley 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. Do not clean with solvent.
Page 77 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 72: Inspecting Timing Belt (1 Of 3) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 77 © 2011 Mitchell Repair Information Company, LLC.
Page 78 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 73: Inspecting Timing Belt (2 Of 3) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 78 © 2011 Mitchell Repair Information Company, LLC.
Page 79 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 74: Inspecting Timing Belt (3 Of 3) Courtesy of HYUNDAI MOTOR CO. REASSEMBLY 1. Install the flange and crankshaft sprocket as shown. Pay close attention to their mounting directions. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 80 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 75: 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 ~ 100 Nm (800 ~ 1000 kg.cm, 59 ~ 74 lb.ft) 3.
Page 81 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 76: Installing Idler Courtesy of HYUNDAI MOTOR CO. 4. Align the timing marks of the camshaft sprocket (A) and camshaft bearing cap (B). Then align the timing marks of crankshaft sprocket and front case with the No.1 piston placed at top dead center on its compression stroke as shown in the illustration.
Page 82 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 77: Identifying Camshaft Sprocket Timing Marks Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 82 © 2011 Mitchell Repair Information Company, LLC.
Page 83 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 78: Aligning Timing Marks Of Crankshaft Sprocket & Front Case 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 84 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 79: 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. (1) Crankshaft sprocket --> (2) Timing belt idler --> (3) Camshaft sprocket -->...
Page 85 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 80: Locating Timing Components Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 85 © 2011 Mitchell Repair Information Company, LLC.
Page 86 (across flats) away from the bolt head center. Fig. 81: Checking Timing Belt Tension Courtesy of HYUNDAI MOTOR CO. 12. Install the timing belt cover. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 87 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 82: Identifying Timing Belt Cover Courtesy of HYUNDAI MOTOR CO. Tightening torque viernes, 19 de febrero de 2021 07:44:32 a. m. Page 87 © 2011 Mitchell Repair Information Company, LLC.
Page 88 140 ~ 150 Nm (1400 ~ 1500 kg.cm, 103 ~ 111 lb.ft) 14. Install the water pump pulley. Fig. 83: Installing Water Pump Pulley Courtesy of HYUNDAI MOTOR CO. 15. Install the alternator belt and adjust the belt tension. 16. Install the air conditioning compressor belt and adjust the belt tension.
Page 89 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent COMPONENTS Fig. 84: Identifying Cylinder Head Components (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 89 © 2011 Mitchell Repair Information Company, LLC.
Page 90 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 85: Identifying Cylinder Head Components (2 Of 2) Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Using a tool remove the cylinder head bolts in the order shown in the illustration.
Page 91 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 86: Identifying cylinder Head Bolt Removal Sequence Courtesy of HYUNDAI MOTOR CO. 2. Using the special tool (09222-28000, 09222-28100), remove the valve retainer lock. Next remove the spring retainer, valve spring, spring seat and valve.
Page 92 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 87: Removing Valve Retainer Locks Courtesy of HYUNDAI MOTOR CO. 3. Remove the valve stem seals with pliers. NOTE: Do not reuse the valve stem seals. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 93 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 88: 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 94 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:32 a. m. Page 94 © 2011 Mitchell Repair Information Company, LLC.
Page 95 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 89: Removing Scale, Sealing Compound & Carbon Deposits From Cylinder Head 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 96 Intake: 0.8 mm (0.028 in.) Exhaust: 1.0 mm (0.040 in.) Fig. 91: Identifying Valve Servicing Limit Courtesy of HYUNDAI MOTOR CO. VALVE SPRINGS 1. Check the free height of each valve spring. If they exceed the serviced limit, replace the springs.
Page 97 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Valve spring [Standard] Free height: 44 mm (1.7323 in.) Load: 21.6 kg/35 mm (47.6 lb/1.3780 in.) 45.1 kg/27.2 mm (99.4 lb/1.0709 in.) Out of square: 1.5° [Limit] Free height: - 1.0 mm (-0.039 in.) Out of square: 3°...
Page 98 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:32 a. m. Page 98 © 2011 Mitchell Repair Information Company, LLC.
Page 99 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 92: Testing Valve Spring Squareness Courtesy of HYUNDAI MOTOR CO. Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with the next oversize part.
Page 100 1. Cut away the inner face of the valve seat to reduce the wall thickness. Fig. 94: Cutting Away Inner Face Of Valve Seat To Reduce Wall Thickness Courtesy of HYUNDAI MOTOR CO. 2. Enlarge the diameter of the valve seat so that it matches the specified oversize hole diameter of the new valve seat ring.
Page 101 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 95: Valve Seat Insert Oversizes Courtesy of HYUNDAI MOTOR CO. REPLACING VALVE GUIDE 1. Using the special tool (09221-3F100 A/B), withdraw the old valve guide toward the bottom of cylinder head.
Page 102 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 96: Installing Valve Guide Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 102 © 2011 Mitchell Repair Information Company, LLC.
Page 103 4. After the valve guide is press-fitted, insert a new valve and check for proper the clearance 5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary. Fig. 97: Valve Guide Oversizes Courtesy of HYUNDAI MOTOR CO. REASSEMBLY NOTE: 1. Clean each part before assembly.
Page 104 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 98: 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 105 Fig. 99: Positioning Valve Springs So Side Coated With Enamel Faces Toward Valve Spring 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 106 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 100: Compressing Spring To Install 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 107 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 101: Cylinder Head Bolt Tightening Sequence Courtesy of HYUNDAI MOTOR CO. Cylinder head bolt 30 Nm (300 kg.cm, 22 lb.ft) + 90° + Release all bolts + 30 Nm(300kg.cm, 22 lb.ft)+90°...
Page 108 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 102: Identifying Camshaft Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Disconnect the breather hose and the P.C.V. hose. 2. Loosen the center cover bolts and then remove the center cover.
Page 109 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 103: Removing Spark Plug Cable Courtesy of HYUNDAI MOTOR CO. 4. Loosen the cylinder head cover bolts and then remove the cylinder head cover. viernes, 19 de febrero de 2021 07:44:32 a. m.
Page 110 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 104: Removing Cylinder Head Cover Courtesy of HYUNDAI MOTOR CO. 5. Remove the camshaft sprocket. viernes, 19 de febrero de 2021 07:44:32 a. m. Page 110 © 2011 Mitchell Repair Information Company, LLC.
Page 111 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 6. Remove the camshaft bearing caps and timing chain. Fig. 105: Removing Camshaft Bearing Caps & Timing Chain Courtesy of HYUNDAI MOTOR CO. 7. Remove the camshaft. 8. Remove the HLA. INSPECTION Camshaft 1.
Page 112 Exhaust: 43.3489 mm (1.7066 in.) Fig. 106: 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 113 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 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 114 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 107: Hydraulic Lash Adjuster (HLA) Trouble Shooting (1 Of 2) Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:33 a. m. Page 114 © 2011 Mitchell Repair Information Company, LLC.
Page 115 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 108: Hydraulic Lash Adjuster (HLA) Trouble Shooting (2 Of 2) Courtesy of HYUNDAI MOTOR CO. NOTE: HLA noise could occur to your engine due to malfunction of HLA if you use additives besides engine oil regulated to HMC.
Page 116 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 109: Inspecting 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 117 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 110: Aligning Camshaft Timing Chain Courtesy of HYUNDAI MOTOR CO. 3. Install the camshaft after lubricating the camshaft journals with engine oil. viernes, 19 de febrero de 2021 07:44:33 a. m.
Page 118 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 111: 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 07:44:33 a. m.
Page 119 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 112: Install Bearing Caps 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 120 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 113: Tightening Bearing Caps 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 121 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 114: Press Fitting Camshaft Oil Seal Courtesy of HYUNDAI MOTOR CO. 7. Install the camshaft sprocket bolts to the specified torque. Tightening torque Camshaft sprocket bolt: 80 ~ 100Nm (800 ~ 1000 kg.cm, 59 ~ 74 lb.ft) viernes, 19 de febrero de 2021 07:44:33 a.
Page 122 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 115: 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. (Refer to the TIMING BELT) 9.
Page 123 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Cylinder head cover bolts: 8 ~ 10 Nm (80 ~ 100 kg.cm, 6 ~ 7 lb.ft) Fig. 116: Installing Cylinder Head Cover viernes, 19 de febrero de 2021 07:44:33 a. m.
Page 124 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Courtesy of HYUNDAI MOTOR CO. 10. Install the spark plug cables, ignition coil assembly and cylinder head center cover. 11. Install the timing belt and then tighten the timing belt tensioner pulley.
Page 125 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 117: Identifying Crankshaft 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 126 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 5. Remove the crankshaft position sensor wheel. CAUTION: Mark the main bearing caps to permit reassembly in the original position and direction. INSPECTION CRANKSHAFT 1. Check the crankshaft journals and pins for damage, uneven wear, and cracks. Also check oil holes for clogging.
Page 127 Clearance between sensor wheel and crank position sensor: 0.5 ~ 1.1 mm (0.020 ~ 0.043 in.) Fig. 118: 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 128 REPLACEMENT 1. Check the cylinder block crankshaft bore size code. Fig. 119: Check Cylinder Block Crankshaft Bore Size Code Courtesy of HYUNDAI MOTOR CO. NOTE: Record the cylinder block crankshaft bore size code letters on cylinder block as shown. Reading order is from left to right with front crankshaft bore size code shown first.
Page 129 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 120: Crankshaft Bore Size Table Courtesy of HYUNDAI MOTOR CO. 2. Check the crankshaft main journal size code. NOTE: Record the main journal size code letters on the crankshaft balance weight.
Page 130 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 121: Recording Main Journal Size Code Letters On Crankshaft Balance Weight Courtesy of HYUNDAI MOTOR CO. CRANKSHAFT MAIN JOURNAL DIAMETER viernes, 19 de febrero de 2021 07:44:33 a. m. Page 130...
Page 131 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 122: Crankshaft Main Journal Diameter Table Courtesy of HYUNDAI MOTOR CO. MAIN JOURNAL BEARING THICKNESS Fig. 123: Main Journal Bearing Thickness (No. 1, 2, 4 & 5) Table Courtesy of HYUNDAI MOTOR CO.
Page 132 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 124: Main Journal Bearing Thickness (No.3) Table Courtesy of HYUNDAI MOTOR CO. 3. Choose proper main journal bearing in table. REASSEMBLY 1. Install the upper main bearing inserts in the cylinder block.
Page 133 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 125: Installing Main Bearing Caps 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 134 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 126: Checking Crankshaft End Play Courtesy of HYUNDAI MOTOR CO. 5. Install the oil seal in the crankshaft rear oil seal case. Use the Special Tool, Crankshaft Rear Oil Seal Installer (09231 - 21000) as shown. Press fit the oil seal all the way in, being careful not to misalign it.
Page 135 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 127: Installing Crankshaft Oil Seal Courtesy of HYUNDAI MOTOR CO. 6. Install the rear plate and tighten the bolts. 7. Install the connecting rod caps. 8. Install the flywheel, front case, oil pan and timing belt. For further details, refer to the respective chapters.
Page 136 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 128: Identifying Flywheel 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. INSPECTION 1. Check the clutch disc contacting surface of the fly wheel for damage and wear. Replace the flywheel if excessively damaged or worn.
Page 137 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Install the flywheel assembly and tighten the bolts to the specified torque. Tightening torque Flywheel bolt: 120 ~ 130 Nm (1200 ~ 1300 kg.cm, 89 ~ 96 lb.ft) PISTON COMPONENTS viernes, 19 de febrero de 2021 07:44:33 a. m.
Page 138 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 129: Identifying Piston Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY OF CONNECTING ROD CAP viernes, 19 de febrero de 2021 07:44:33 a. m. Page 138 © 2011 Mitchell Repair Information Company, LLC.
Page 139 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 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 140 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 130: Disassembling Connecting Rod Cap Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY AND REASSEMBLY OF THE PISTON PIN 1. Using the special tools, disassemble and reassemble the piston and connecting rod.
Page 141 Fig. 132: Installing Pin Guide 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. Continue pressing until the pin guide falls free and the installer tool seats against the top of the arch.
Page 142 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent CAUTION: Do not exceed 1250 +/- 500 kg (2765 +/- 1102 lb) of force when the installing tool seats against the top of the arch. viernes, 19 de febrero de 2021 07:44:33 a. m.
Page 143 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 133: Installing Piston Pin 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 144 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 134: Measuring Piston Ring Side Clearance Courtesy of HYUNDAI MOTOR CO. 2. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles in the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge.
Page 145 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent [Standard dimensions] No. 1: 0.15 ~ 0.30 mm (0.0059 ~ 0.012 in.) No. 2: 0.30 ~ 0.45 mm (0.012 ~ 0.018 in.) Oil ring side rail: 0.2 ~ 0.7 mm (0.0079 ~ 0.0276 in.) [Limit] No.
Page 146 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 135: Measuring Piston Ring End Gap Courtesy of HYUNDAI MOTOR CO. When replacing the ring without correcting the cylinder bore, check the gap with the ring situated at the low part of cylinder that is less worn out.
Page 147 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 136: Piston Ring Service Size & Mark Table Courtesy of HYUNDAI MOTOR CO. NOTE: The mark can be found on the upper side of the ring next to the end.
Page 148 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 137: Inspecting Connecting Rods Courtesy of HYUNDAI MOTOR CO. REPLACEMENT 1. Check the cylinder bore size code on the cylinder block bottom face. viernes, 19 de febrero de 2021 07:44:33 a. m.
Page 149 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 138: Check Cylinder Bore Size Code On Cylinder Block Bottom Face Courtesy of HYUNDAI MOTOR CO. viernes, 19 de febrero de 2021 07:44:33 a. m. Page 149 © 2011 Mitchell Repair Information Company, LLC.
Page 150 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 139: Cylinder Bore Inner Diameter Table Courtesy of HYUNDAI MOTOR CO. 2. Check the piston size code on the piston top face. Fig. 140: Check Piston Size Code On Piston Top Face Courtesy of HYUNDAI MOTOR CO.
Page 151 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 141: Piston Outer Diameter Table Courtesy of HYUNDAI MOTOR CO. 3. Select the piston related to cylinder bore class. Oil clearance 0.025 ~ 0.045mm (0.00098 ~ 0.00177in.) REASSEMBLY 1. Install the spacer.
Page 152 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent viernes, 19 de febrero de 2021 07:44:33 a. m. Page 152 © 2011 Mitchell Repair Information Company, LLC.
Page 153 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 142: Installing Spacer & Side Rail 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 154 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 144: Installing Piston Ring 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 155 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 145: Identifying Ring 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 156 Standard: 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.) Limit: 0.4 mm (0.0157 in.) Fig. 146: Checking Connecting Rod Side Clearance Courtesy of HYUNDAI MOTOR CO. 15. Install the oil screen. 16. Install the oil pan. 17. Install the cylinder head.
Page 157 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent LUBRICATION SYSTEM OIL PUMP COMPONENTS viernes, 19 de febrero de 2021 07:44:33 a. m. Page 157 © 2011 Mitchell Repair Information Company, LLC.
Page 158 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 147: Identifying Lubrication System Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Remove the timing belt. 2. Remove all the oil pan bolts. 3. Remove the oil pan. 4. Remove the oil screen.
Page 159 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 149: Removing Oil Pump Cover Courtesy of HYUNDAI MOTOR CO. 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 160 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Check the surfaces contacting the gears for damage or wear. OIL PUMP GEARS 1. Check the gear tooth surfaces for wear or damage. 2. Measure the clearance between outer gear and front case.
Page 161 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 150: 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 07:44:33 a. m.
Page 162 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 151: Checking Tip Clearance On Pump Rotor Courtesy of HYUNDAI MOTOR CO. RELIEF VALVE AND SPRING viernes, 19 de febrero de 2021 07:44:33 a. m. Page 162 © 2011 Mitchell Repair Information Company, LLC.
Page 163 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent 1. Check sliding condition of the relief valve inserted in the front case. 2. Inspect for distorted or broken relief valve spring. 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.
Page 164 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 152: Checking Oil Pressure Switch 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 165 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 153: Testing Oil Pressure Switch Courtesy of HYUNDAI MOTOR CO. 3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly.
Page 166 8~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb.ft) Fig. 154: Installing Oil Pump Cover Courtesy of HYUNDAI MOTOR CO. 3. Install the relief valve and spring. Tighten the plug to the specified torque. Apply engine oil to the relief valve.
Page 167 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 155: Installing Relief Valve & Spring 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 168 2004 ENGINES 1.6L 4-Cylinder - Accent D : 22 mm (0.89 in.) Fig. 156: Installing Front Case Assembly Courtesy of HYUNDAI MOTOR CO. OIL SEAL 1. Using the special tool, Crankshaft oil seal guide(09231-22100), install the oil seal. 2. Using the special tool, Crankshaft front oil seal installer (09231-22000), install the oil seal.
Page 169 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 157: Installing Crankshaft Front Oil Seal Courtesy of HYUNDAI MOTOR CO. 3. Install the oil screen. 4. Clean both gasket surfaces of the oil pan and the cylinder block. 5. Apply sealant into the groove of the oil pan flange as shown.
Page 170 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 158: 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 171 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent COMPONENTS Fig. 159: Identifying Engine Block Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY viernes, 19 de febrero de 2021 07:44:34 a. m. Page 171 © 2011 Mitchell Repair Information Company, LLC.
Page 172 1. Remove the timing belt, cylinder head, front case, flywheel, pistons and crankshaft. 2. Remove the oil pressure switch. Fig. 160: Removing Oil Pressure Switch Courtesy of HYUNDAI MOTOR CO. INSPECTION 1. Check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Replace the block if defective.
Page 173 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 161: 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 174 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 162: Checking Cylinder Bores For Out-Of-Round Or Taper 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 175 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 163: Measuring Piston Outside Diameter Courtesy of HYUNDAI MOTOR CO. ENGINE MOUNTS COMPONENTS viernes, 19 de febrero de 2021 07:44:34 a. m. Page 175 © 2011 Mitchell Repair Information Company, LLC.
Page 176 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 164: Identifying Engine Mounts & Components Courtesy of HYUNDAI MOTOR CO. REMOVAL Attach an engine hoist to the engine hooks, and raise the engine just enough so that there is no pressure on the insulators.
Page 177 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 165: Lifting Engine With Hoist Courtesy of HYUNDAI MOTOR CO. ENGINE MOUNTING Remove the engine mounting support bracket from the engine. viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 178 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 166: Removing Engine Mounting Support Bracket From Engine Courtesy of HYUNDAI MOTOR CO. TRANSMISSION MOUNTING 1. Remove the air cleaner. viernes, 19 de febrero de 2021 07:44:34 a. m. Page 178...
Page 179 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 167: Removing Air Cleaner Courtesy of HYUNDAI MOTOR CO. 2. Remove the transmission mounting bolt. (17 mm) viernes, 19 de febrero de 2021 07:44:34 a. m. Page 179 © 2011 Mitchell Repair Information Company, LLC.
Page 180 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 168: Removing Transmission Mounting Bolt Courtesy of HYUNDAI MOTOR CO. 3. Detach the cap from inside the right fender shield. Remove the transmission mounting bolts. (14 mm) viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 181 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 169: Detaching Cap From Inside Right Fender Shield Courtesy of HYUNDAI MOTOR CO. 4. Remove the transmission bracket. FRONT ROLL STOPPER BRACKET Remove the roll rod bracket from the cross member.
Page 182 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 170: Removing Roll Rod Bracket From Cross Member Courtesy of HYUNDAI MOTOR CO. REAR ROLL STOPPER BRACKET Remove the rear roll stopper bracket from the sub frame. viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 183 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 171: Removing Rear Roll Stopper Bracket From Sub Frame Courtesy of HYUNDAI MOTOR CO. INTAKE AND EXHAUST SYSTEM EXHAUST MANIFOLD COMPONENTS viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 184 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 172: Identifying Exhaust System Components Courtesy of HYUNDAI MOTOR CO. DISASSEMBLY 1. Disconnect the oxygen sensor connect. viernes, 19 de febrero de 2021 07:44:34 a. m. Page 184 © 2011 Mitchell Repair Information Company, LLC.
Page 185 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 173: Locating Oxygen Sensor Connector Courtesy of HYUNDAI MOTOR CO. 2. Remove the exhaust manifold heat protector. 3. Remove the exhaust manifold assembly from the cylinder head. 4. Remove the exhaust manifold gasket.
Page 186 CAUTION: Replace the exhaust manifold gasket and lock nut when reassembling. INTAKE MANIFOLD COMPONENTS Fig. 174: Identifying Intake Manifold Components Courtesy of HYUNDAI MOTOR CO. REMOVAL 1. Disconnect the MAP, ISA and TPS connect. viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 187 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 175: Disconnecting MAP, ISA & TPS connectors Courtesy of HYUNDAI MOTOR CO. 2. Remove the intake air hose connected to the throttle body. 3. Remove the accelerator cable. 4. Remove the PCV hose and brake booster vacuum hoses.
Page 188 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 176: Removing PCV Hose & Brake Booster Vacuum Hoses Courtesy of HYUNDAI MOTOR CO. 5. Disconnect the coolant hose connections front the throttle body. viernes, 19 de febrero de 2021 07:44:34 a. m.
Page 189 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 177: Disconnecting Coolant Hose Connections Front Throttle Body Courtesy of HYUNDAI MOTOR CO. 6. Disconnect the fuel injector harness connector. viernes, 19 de febrero de 2021 07:44:34 a. m. Page 189...
Page 190 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 178: Disconnecting Fuel Injector Harness Connector Courtesy of HYUNDAI MOTOR CO. 7. Remove the delivery pipe with the fuel injectors. viernes, 19 de febrero de 2021 07:44:34 a. m. Page 190...
Page 191 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 179: Removing Delivery Pipe With Fuel Injectors Courtesy of HYUNDAI MOTOR CO. 8. Remove the intake manifold stay. viernes, 19 de febrero de 2021 07:44:34 a. m. Page 191 © 2011 Mitchell Repair Information Company, LLC.
Page 192 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 180: Removing Intake Manifold Stay Courtesy of HYUNDAI MOTOR CO. 9. Remove the intake manifold. 10. Remove the intake manifold assembly and gasket. INSPECTION INTAKE MANIFOLD Check the parts for damage or cracking.
Page 193 CAUTION: Be careful not to drop the injectors when removing the delivery pipe. Fig. 181: Installing Delivery Pipe With Fuel Injectors Courtesy of HYUNDAI MOTOR CO. 4. Connect the fuel injector harness connector. 5. Install the P.C.V. hose and brake booster vacuum hose.
Page 194 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent COMPONENTS Fig. 182: Identifying Muffler Components Courtesy of HYUNDAI MOTOR CO. REMOVAL REAR MUFFLER CAUTION: Before removing or inspecting the exhaust system, ensure that the exhaust system is cool. 1. Disconnect the rear muffler from the center muffler.
Page 195 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 183: Removing Rubber Hangers Courtesy of HYUNDAI MOTOR CO. CENTER MUFFLER 1. Remove the center muffler assembly from the rear muffler and front exhaust pipe. 2. Remove the rubber hanger, then remove the center muffler.
Page 196 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 184: Removing Center Muffler Assembly From Rear Muffler & Front Exhaust Pipe Courtesy of HYUNDAI MOTOR CO. FRONT EXHAUST PIPE 1. Remove the front exhaust pipe clamp bolts. and remove the front exhaust pipe nuts from the catalytic converter.
Page 197 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 185: 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 rear muffler, in that order.
Page 198 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 186: Identifying Air Cleaner Components Courtesy of HYUNDAI MOTOR CO. REMOVAL 1. Remove the air duct connected to the air cleaner. 2. Remove the air intake hose at the air cleaner side.
Page 199 2004 Hyundai Accent 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 187: Removing Air Cleaner Mounting Bolts & 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 200 3. Check the resonator for distortion or damage. Fig. 188: 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 201 2004 ENGINES 1.6L 4-Cylinder - Accent Fig. 189: Removing Dust & Other Contaminants By Blowing Compressed Air From Upper Side Through 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.

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