Content list

Page
• For the (Hyundai Accent 2010 DOHC_G 1.6 L)
1. Explain the engine disassemble steps, tools and technique must be used to do the task
in safe and proper sequence according to the workshop repair manual. .... 1-2-3-4-5-6-7
2. Inspect and Analyze wear and damage of the following items of cylinder head and
engine block:
a. Surface flatness ................................................................................................ 7
b. Cylinder head gasket ......................................................................................... 8
c. Valve assembly visual check (valve seat, Valve spring free length, diameter)..8-9
d. Cam shaft, crank shaft roundness ..................................................................... 10-11
e. Cylinder bore ..................................................................................................... 11
f. Piston and piston rings ....................................................................................... 12
3. After analyze the last items with the repair manual Select the required procedures for
repair them. .............................................................................................................. 12
4. Explain the procedure to inspect cooling system parts (cooling pump, radiator,
thermostat) to suggest the ability to reuse or replace any faulty parts. .................... 13
5. For the Hyundai Tucson TL 2015+ 1.6L; Explain the engine reassembly steps, tools
and technique must be done to perform the task in safe and proper sequence according
to the workshop repair manual. ........................................................................ 14-15-16-17
6. Carry out adjustment for engine valve timing chain and belts tension and make all
required adjustments prior to starting an engine. (Represent the procedures, tools must
be used, tension values) ...................................................................................... 17-18-19-20
7. For Hyundai Accent 2010 DOHC_G 1.6 L carry out the measurement inspections of
the following items:
a. Engine cylinder head and block flatness ............................................................. 20
b. Cylinder bore ....................................................................................................... 21
c. Piston rings .......................................................................................................... 21
d. Spark plugs ........................................................................................................... 22
Insert the measured value in table then Compare between the measured value with the
recommended value in repair manual. .......................................................................... 22
8. Describe how to Evaluate and justify the after inspection, repair to ensure it will
work with satisfied performance (list the test must be used to evaluations) ........... 23-24
 ➢ Tasks:
• For the (Hyundai Accent 2010 DOHC_G 1.6 L)
1. Explain the engine disassemble steps, tools and technique must be used
to do the task in safe and proper sequence according to the workshop
repair manual.
1. Drain the engine oil and coolant:
Before beginning the disassembly process, drain the engine oil and coolant, and remove the
battery cables to prevent any electrical hazards.

Figure 1. Drain the engine oil Figure 2. Drain the engine oil and coolant

2. Remove hoses and wire electricity engine :

- remove fuel hose / remove radiator hoses / Remove the ignition coil / remove sensors

Figure 3. remove fuel hose Figure 4. remove radiator hoses

Figure 5. Remove the ignition coil Figure 6. remove sensors

3.Remove the brake booster vacuum hose(B)

Figure 7. Remove the brake booster vacuum hose

4.Remove the exhaust manifold.

Figure 8 Remove exahust mainfold

5.Remove air intake system :

Remove the air intake system, including the air filter, air inlet hose, and mass airflow
sensor.and intake mainfold

Figure 9. air intake system components

6.Remove the timing belt and related components: related components, including the
tensioner, idler pulley, and water pump.
- Remove the 4 bolts(B) and timing belt lower cover(A)

Figure 10. Remove cover timing belt

- Remove the timing belt tensioner(A) and timing belt

Figure 11. Remove the timing belt

7. Remove the cylinder head cover (A)

Figure 12. cylinder head cover

8.Remove the camshaft sprocket
9. Remove the timing chain auto tensioner(A)

Figure 13. timing chain auto tensioner

10. Remove the camshaft bearing caps(A) and camshafts (B)

Figure 14. Remove the camshaft bearing caps and camshafts

11- Remove the cylinder head bolts, then remove the cylinder head. Using 8mm hexagon
wrench, uniformly loosen and remove the 10 cylinder head bolts

Figure 15. Remove the cylinder head bolts

12. Remove the HLAS(A)

Figure 16. HLAS

13. Remove the valves. (1) Using the SST (09222-28000, 09222-28100), compress the valve spring
and remove the retainer lock

Figure 17..Remove the valves

14. Remove the spring retainer

15. Remove the valve spring
16. Remove the valve
17. Using a needle-nose pliers, remove the oil seal
18. Using a magnetic finger, remove the spring seat
19. Remove the water pump.
20. Remove the oil pan(A)

Figure 18. Remove the oil pan

21. Remove the 2bolts(C), oil screen(A) and gasket(B)

Figure 19.remove oil screen

22. Remove the connecting rod caps

23. Remove the piston and connecting rod assemblies

Figure 20. Remove the connecting rod caps

24. Remove the 5bolts (B) and rear oil seal case(A).

Figure 21.Remove rear oil seal case

25. Lift the crankshaft(A) out of the engine

Figure 22. Lift the crankshaft out of the engine

 • Tools and techniques:
To safely and properly disassemble the engine, it is important to use the following
tools and techniques:
1. Engine hoist: An engine hoist is necessary to lift and remove the engine from the vehicle.
2. Torque wrench: A torque wrench is necessary to properly tighten bolts and nuts to the
manufacturer's specifications.
3. Socket set: A socket set is necessary to remove and install bolts and nuts.
4. Labeling system: A labeling system, such as masking tape and a marker, is necessary to
label components and keep track of their positions during disassembly.
5. Reference material: The workshop repair manual should be used as a reference to ensure
proper disassembly and reassembly of the engine components.

2. Inspect and Analyze wear and damage of the following items of cylinder head
and engine block:
a. Surface flatness.
b. Cylinder head gasket
c. Valve assembly visual check (valve seat, Valve spring free length, diameter).
d. Cam shaft, crank shaft roundness .
e. Cylinder bore.
f. Piston and piston rings.
- cylinder head:
1. incpect Surface flatness :
• Visual ivspection
- Result : cylinder head cracked
• If not cracked
Using a precision straight edge and feeler gauge, measure the surface the contacting the
cylinder block and the manifolds for warpage.
- Flatness of manifold mating surface
Standard: Less than 0.15mm (0.0059in) / Limit: 0.20mm (0.0079in)

figure 23. Inspect for flatness.

2. inspect Cylinder head gasket
- Check head gasket from damage
• result
- There is nothing in it
Standard : Less than 0.03mm (0,0012in) / Limit: 0.05mm (0.0020in)

3. Valve assembly visual check (valve seat, Valve spring free length, diameter).
- visual Inspect valve
• Check the valve is ground to the correct valve face angle.
• Check the surface of valve for wear
• Check the valve head margin thicknessIf the margin thickness is less than minimum,
replace the valve

Figure 24. Margin valve and valve face angle.

• Margin Standard
Intake: 1.1mm (0.0433in) / Exhaust: 1.3mm (0.0512in)
• Limit
Intake: 0.8mm (0.0315in) / Exhaust: 1.0mm (0.0394in)

• Result :
- All sizes are correct according to the service manual

• valve seat :
- Check the valve seat improper contact with the
valve face.
- check the valve guide for wear
• Result
- valve guide is worn
- valve face improper contact with valve seat Figure 25. valve seat and valve guide
- 4. Inspect Valve spring free length :
- Using vernier calipers, measure the free
length of valve spring
• Spring Standard
- Free height: 44mm (1.7323in)
- Load: 21.6±1.1kg/35.0mm
(47.6±2.4lb/1.3780in)
45.1+2.2kg/27.2mm
(99.4+4.91b/1.0709in Figure 26. Inspect Valve spring free length
• Result
- Free height : 35 mm
- At load 21.6 ± 1.1kg / 25.0mm

• Inspect valve diameter and valve guide :

• valve guides.
- Using a caliper gauge, measure the
inner diameter of valve guide.
Valve guide inner diameter:
6.000-6.015mm (0.2362-0.2368in)

Figure 27. Inspect inner diameter valve guide

• valve diameter
- Using a micrometer, measure the
outer diameter of valve stem
- Valve stem outer diameter
Intake: 5.965~5.980mm (0.2348~0.2354in)
Exhaust:5.950~5.965mm(0.2343~0.2348in
• Valve stem - guide = clearance
- Standard Intake: 0.02 - 0.05mm
(0.0008~0.0020in) Figure 28. Inspect valve diameter
- Exhaust: 0.035~0.065mm (0.0014
0.0026in)
• Limit
Intake: 0.10mm (0.0039in)
Exhaust: 0.15mm (0.0059in)
• Result :
- Valve guide inner diameter : 6.035mm
- Valve stem outer diameter : 5.940 mm
- Valve stem - guide = clearance : 0.095 mm
5. inspect Cam shaft, crank shaft roundness :

• Inspect Cam shaft

- Using a micrometer, measure the cam lobe
height
• Cam height :
Intake: 43.7492~43.9492mm (1.72241~
1.73028in)
Exhaust: 44.1494~44.3494mm (1.73816~ Figure 29.incpect cam lobe height
1.74604in)
• Inspect the camshaft journal
clearance.
- Place the camshafts on the cylinder head.
- Lay a strip of plastigage across each of the
camshaft journal
- Install the bearing caps and tighten the
bolts with specified torque
- Remove the bearing caps
- Measure the plastigage at its widest poin
• Bearing oil clearance stander Figure 30.Inspect the camshaft journal
- Standard: 0.020~0.061mm (0.0008 ~ clearance.
0.0024in)
- Limit: 0.1mm (0.0039in)
• Inspect the camshaft end play.
- Install the camshafts.
- Using a dial indicator, measure the end
play while moving the camshaft back and
forth.
• Camshaft end play
Standard: 0.1 ~ 0.2mm (0.0039 ~ 0.0079in)

Figure 31. Inspect the camshaft end play

• Result
• Cam height : Intake : 43.7492~43.9492mm / Exhaust: 44.1494~44.3494mm
• Bearing oil clearance : 0.061mm
Camshaft end play : 0.2mm
 • Inspect crank shaft roundness :
• crank shaft roundness
- checked with a dial bore gauge or
telescoping gauge and micrometer
- install and tighten the main bearing caps,
then measure the inside diameter in many
places in each bore
• Maxiumam roundness
- 0.08mm Figure 32. Inspect crank shaft roundness

• Result :
- Roundness : 0.025mm

5. inspect Cylinder bore :

• Visually check :
- check the cylinder for vertical scratchs.
• Inspect cylinder bore diameter :
- Using a cylinder bore gauge, measure the
cylinder bore diameter at position in the thrust
and axial direction
• Standard diameter:
1.6 CVVT : 76.50 – 76.53mm
- Check the cylinder bore size code on the Figure 33. Inspect cylinder bore diameter
cylinder block bottom face. Show in
Table 1
Mark cylinder bore inner diameter
A 76.50 - 76.51mm
B 76.51 - 76.52mm
C 76.52 - 76.53mm

Figure 34. cylinder bore mark

• Result :
- There are no vertical scratches
- cylinder bore diamete : 76.50 mm
6. inspect Piston and piston rings :
• inspect Piston
- clean the carbon from the piston top
- clean the piston ring grooves
- Using micrometer, measure the piston
outside diameter is taken,
39.15mm(1.5413in) from top land of the
piston.
• Standard diameter:
76.47-76.50mm (3.0106-3.0118in)
- Calculate the difference between the
cylinder bore inner diameter and the Figure 35. measure the piston outside diameter
piston outer diameter
• Piston-to-cylinder clearance:
0.02 - 0.04mm (0.0008 - 0.0016in)
• Result :
- piston outside diameter : 76.50mm
- Piston-to-cylinder clearance ; 0.04mm

• Inspect piston ring

- visual inspection : check piston ring from any damage

3. After analyze the last items with the repair manual Select the required
procedures for repair them.
inspected Result Solution
Surface flatness - Cylinder head cracked Replace cylinder head
valve seat - valve guide is worn Replace valve giide
- valve face improper Replace valve seat
contact with valve seat
valve Spring - Free height : 35 mm Replace valve sprnig
- At load 21.6 ± 1.1kg /
25.0mm
Cranck shaft Roundness - Roundness : 0.025mm - We machining the crank
and then put the bearing in
the same thickness as what
was machining
4. Explain the procedure to inspect cooling system parts (cooling pump,
radiator, thermostat) to suggest the ability to reuse or replace any faulty
parts
• cooling pump
- Check the pump for any signs of leaks or
damage.
- Check the pump impeller for any signs of
wear or damage.
- Check the pump shaft for any signs of
wear or damage.
- Check the pump bearings for any signs of
wear or damage.
• the pump should be replaced.
Figure 36.check water pump

• radiator
- Check the radiator for any signs of leaks or
damage.
- Check the radiator fins for any signs of
damage or blockage.
- Check the radiator hoses for any signs of
wear or damage.
- Check the radiator cap for any signs of
wear or damage.
- Cooling Circuit Sealing Check
• Radiator should be placed Figure 37. radiator leaks

• Thermostat
- Check the thermostat for any signs of wear
or damage, such as corrosion or cracks.
- Test the thermostat by placing it in a pot of
boiling water. The thermostat should open
fully at the specified temperature and close
fully when removed from the water and
allowed to cool.
- Check the thermostat housing for any
signs of wear or damage. Figure 38. damaged thermostat
• Thermostat should be placed
5. For the Hyundai Tucson TL 2015+ 1.6L; Explain the engine reassembly
steps, tools and technique must be done to perform the task in safe and proper
sequence according to the workshop repair manual.
1. Install main bearings (A)

figure 39. Install main bearings

2. Install thrust bearings.(A)

figure 40. Install thrust bearings.

3. Place crankshaft(A) on the cylinder block.

- Ispect clearance betwwan cranck and bearing cap

Figure 41. Place crankshaf

4. Install main bearing cap bolts Tightening torque 14.7Nm

Figure 42. Install main bearing cap

 • Inspect piston ring side clearance
- Using a feeler gauge, measure the
clearance between new piston ring and the
wall of ring groove.
• Piston ring side clearance
- No.1 ring: 0.04 0.085mm
- No.2 ring: 0.04 0.085mm
- Oil ring: 0.08 0.175mm
• Limit
- No.1 ring: 0.1mm (0.0039in)
- No.2 ring: 0.1mm (0.0039in) Figure 43. Measure piston ring side clearance
• Inspect the piston ring end gap.
- insert a piston ring into the cylinder bore
- Position the ring at right angles to the cylinder
wall by gently pressing it down with a piston
- Measure the gap with a feeler gauge
- If the gap is too large, recheck the cylinder
bore inner diameter.
- If the bore is over the service limit, the
cylinder block must be rebored.
• Piston ring end gap Standard
No.1 ring : 0.15 0.30mm
No.2 ring : 0.35 0.50mm
Oil ring : 0.20 0.70mm
• Limit Figure 44. Inspect the piston ring end gap
No1, 2, oil ring: 1.0mm
5. Use a ring compressor to compress the piston rings, and install the piston and rod assembly
into the cylinder bore.

Figure 45. install the piston and rod assembly into the cylinder bore.

6. Apply liquid gasket to the mating surface of cylinder block and ladder frame

Figure 46. liquid gasket to the mating surface of cylinder block

7. Install (oil pump).
8. Install water pump.
9. Engine sensors

Figure 47. oil pressure sensor and Install knock sensor

10. Install the cylinder head. (Refer to Cylinder head assembly in this group)

Figure 48. Cylinder head assembly in this group

11. Install the timing chain. (Refer to Timing system in this group) chain, tensioner, and
sprockets
12. Install intake manifold, exhaust manifold
13. Install the oil pan(A)

Figure 49. Install the oil pan

13.: Install drive plate

Figure 50. Install fly wheel

• Tools and techniques: To safely and properly reassemble the engine, it is important
to use the following tools and techniques:
1. Torque wrench
2. Socket set
3. Ring compressor
4. Labeling system
5. Reference material
6. Lubricants: Lubricants, such as engine oil

6. Carry out adjustment for engine valve timing chain and belts tension and
make all required adjustments prior to starting an engine. (Represent the
procedures, tools must be used, tension values).
- Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface
of main bearing cap.
- Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and
exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of
this, the piston of No.1 cylinder is placed at the top dead center on compression stroke

Figure 51. Set the crankshaft. the intake and exhaust CVVT sprockets
- Install the timing chain guide (A). / Tightening torque : 9.8 ~ 11.8N.m

Figure 52. Install the timing chain guide

- Install the timing chain.

To install the timing chain with no slack between each shaft (cam, crank), follow the below
procedure.Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT assembly (C)
→ Exhaust CVVT assembly (D). The timing mark of each sprockets should be matched with
timing mark (color link) of timing chain at installing timing chain

Figure 53.54.55. Install the timing chain

- Install the timing chain tensioner arm (B). / Tightening torque : 9.8 ~ 11.8N.m
- . Install the timing chain auto tensioner (A) and remove the set pin.

Figure 56..Install the timing chain auto tensioner

- After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front),
confirm the timing mark

Figurt 57. confirm the timing mark

- Install timing chain cover

Figure 58. Install timing chain cover

 • belts tension
- Recheck the tension by Using a tension
gauge

Figure 59 . Recheck the tension

7. For Hyundai Accent 2010 DOHC_G 1.6 L carry out the measurement
inspections of the following items:
a. Engine cylinder head and block flatness
b. Cylinder bore
c. Piston rings
d. Spark plugs
Insert the measured value in table then Compare between the measured
value with the recommended value in repair manual.
a. incpect Surface flatness for cylinder head
- Visual ivspection
- Using a precision straight edge and feeler gauge,
measure the surface the contacting the cylinder
block and the manifolds for warpage.
- Flatness surface
Standard: Less than 0.03mm

Figure 60. incpect Surface flatness

• Inspect the top surface flatness for
cylinder block
- Visual ivspection
- Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head
gasket for warpage.
• Flatness of cylinder block surface
Standard: Less than 0.05mm
Figure 61. incpect Surface flatness
b. cylinder bore
• Visually check :
- check the cylinder for vertical scratchs.
• Inspect cylinder bore diameter :
- Using a cylinder bore gauge, measure the
cylinder bore diameter at position in the thrust
and axial direction
• Standard diameter:
1.6 CVVT : 76.50 – 76.53mm Figure 62. Inspect cylinder bore diameter
- Check the cylinder bore size code on the
cylinder block bottom face. Show in
Table 2
Mark cylinder bore inner diameter
A 76.50 - 76.51mm
B 76.51 - 76.52mm
C 76.52 - 76.53mm
Figure 63. cylinder bore mark
C. piston ring
• Inspect piston ring side clearance
- Using a feeler gauge, measure the
clearance between new piston ring and the
wall of ring groove.
• Piston ring side clearance
- No.1 ring: 0.04 - 0.085mm
- No.2 ring: 0.04 - 0.085mm
- Oil ring: 0.08 - 0.175mm
• Limit
- No.1 ring: 0.1mm
- No.2 ring: 0.1mm Figure 64. Measure piston ring side clearance
• Inspect the piston ring end gap.
- insert a piston ring into the cylinder bore
- Position the ring at right angles to the cylinder
wall by gently pressing it down with a piston
- Measure the gap with a feeler gauge
- If the gap is too large, recheck the cylinder
bore inner diameter.
- If the bore is over the service limit, the
cylinder block must be rebored.
• Piston ring end gap Standard
No.1 ring : 0.15 - 0.30mm
No.2 ring : 0.35 - 0.50mm
Oil ring : 0.20 - 0.70mm
• Limit Figure 65. Inspect the piston ring end gap
No1, 2, oil ring: 1.0mm
d. Spark plugs
• Visual inspection
- Check the spark plug for any
corrosion, cracking, or carbon buildup
on the electrode
- checking and setting the gap
- check Internal resistance
Figure 66. Inspect spark plug
Stander air gap : 1.0 ~ 1.1 mm
Stander Internal resistance: 5-15 KO

Figure 67. Inspect air gap

(Compare) show in table 3
measured value Stander value
• flatness for cylinder head : 0.02mm • flatness for cylinder head : less
• Flatness for cylinder blok : 0.04mm 0.03mm
• Flatness for cylinder blok : less
0.05mm
• Cylinder bore : 76.50mm • Cylinder bore : 76.50
• Piston-to-cylinder clearance: 0.02 • Piston-to-cylinder clearance: less 0.04
• Piston ring side clearance • Piston ring side clearance
- No.1 ring: 0.04 mm Limit
- No.2 ring: 0.04 mm - No.1 ring: 0.1mm
- Oil ring: 0.07 mm - No.2 ring: 0.1mm
• Piston ring end gap Standard - Oil ring: 0.08mm
No.1 ring : 0.15mm • Piston ring end gap Standard
No.2 ring : 0.35mm • Limit
Oil ring : 0.20 mm No1, 2, oil ring: 1.0mm
• Spark plug • Spark plug
- Air gap : 1.0mm - Air gap : 1.0 ~ 1.1 mm
- Internal resistance : 1.5 KO - Internal resistance: 5-15 KO
8. Describe how to Evaluate and justify the after inspection, repair to ensure it
will work with satisfied performance (list the test must be used to evaluations)
• After assemble
- Evaluation For Hyundai Tucson TL 2015+ 1.6L
Dry Compression Test
- Disconnect the injector connectors (A) and
ignition coil connectors (B)
-. Remove ignition coils
- . Remove spark plugs. Using a 16mm plug
wrench, remove the 4 spark plugs
- Check cylinder compression pressure. A.
Insert a compression gauge into the spark
plug hole.
- Fully open the throttle. Figure 68.Dry Compression Test
- While cranking the engine, measure the
compression pressure.
Compression pressure :
1,283kPa (185psi)
Minimum pressure :
1,135kPa (164psi)
Difference between each cylinder :
100kPa (15psi) or less
• Result
C1 = 175 psi Figure 69. Dry Compression Test
C2 = 179 psi
C3 = 176 psi
C4 = 180psi
• Evaluations
- Engine compression is excellent and
has no problem
- Evaluation For (Hyundai Accent 2010 DOHC_G 1.6 L)
Dry Compression Test
- Disconnect the injector connectors and
ignition coil connectors
-. Remove ignition coils
- . Remove spark plugs. Using a 16mm plug
wrench, remove the 4 spark plugs
- Check cylinder compression pressure. A.
Insert a compression gauge into the spark
plug hole.
- Fully open the throttle.
- While cranking the engine, measure the
compression pressure.
Figure 70.
Standard:
1,422kPa (206psi) (250-400 rpm)
Minimum:
1,275kPa (185psi)
Difference between each cylinder:
98kPa (14psi) or less
• Rsult
C1 = 200 psi
C2 = 201 psi
C3 = 205 psi Figure 71
C4 = 202psi
• Evaluations
- Engine compression is excellent and
has no problem