Brenicscope 94

1994 Hyundai Scoupe
1.5L 4-CYL - VIN [N] 1994 HYUNDAI ENGINES 1.5L 4-Cylinder
1.5L 4-CYL - VIN [N]
1994 HYUNDAI ENGINES 1.5L 4-Cylinder
ENGINE IDENTIFICATION
NOTE: For engine repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL
INFORMATION section.
The 6th character in Vehicle Identification Number (VIN) identifies engine type. Engine identification code is
stamped at top right front side of cylinder block.
ENGINE IDENTIFICATION CODES

Application Engine Code VIN Code
Scoupe
1.5L 4-Cylinder (1)
G4AER N
(1) Third character may not be the same for all 1.5L engines.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
1. Ensure head bolts are properly tightened before adjusting valves. Ensure engine is at normal operating
temperature. Rotate crankshaft clockwise to position cylinder No. 1 on TDC of compression stroke.
2. Adjust valves on cylinder No. 1. See VALVE CLEARANCE SPECIFICATIONS table. Rotate crankshaft
clockwise to position cylinder No. 3 on TDC of compression stroke.
3. Adjust valves on cylinder No. 3. Rotate crankshaft clockwise to position cylinder No. 4 on TDC of
compression stroke.
4. Adjust valves on cylinder No. 4. Rotate crankshaft clockwise to position cylinder No. 2 on TDC of
compression stroke. Adjust valves on cylinder No. 2.
VALVE CLEARANCE SPECIFICATIONS

Application In. (mm)
Hot (1)
Intake .010 (.25)
Exhaust .012 (.30)
Cold
Intake .007 (.18)
Exhaust .009 (.24)
(1) 176-203° F (80-95° C) coolant temperature.
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1994 Hyundai Scoupe
REMOVAL & INSTALLATION
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.
FUEL PRESSURE RELEASE
WARNING: Relieve fuel pressure before disconnecting any fuel injection-related

component. DO NOT allow fuel to contact engine or electrical
components.
Disconnect fuel pump harness connector at rear of fuel tank. Start engine. After engine stalls, turn ignition
switch to OFF position. Disconnect negative battery cable.
ENGINE
Removal
1. Engine and transaxle are removed as a unit. Drain transaxle oil and cooling system. Release fuel pump
pressure. See FUEL PRESSURE RELEASE. Remove battery and air cleaner assembly.
2. Label and disconnect electrical connections and vacuum hoses from engine and transaxle. On A/T
models, mark and disconnect transaxle cooler lines. Plug cooler lines.
NOTE: Mark transaxle cooler line location before removal. Install lines in original
location.
3. Disconnect radiator and heater hoses and remove radiator. Disconnect fuel hoses and accelerator cable.
Disconnect A/C compressor and mounting bracket (if equipped).
4. Disconnect speedometer cable at transaxle. On M/T models, disconnect clutch cable, shift control rod and
extension rod. On A/T models, disconnect shift control cable from transaxle.
5. On all models, raise and support vehicle. Disconnect exhaust pipe and support with wire. Remove
underbody cover. Remove lower ball joint-to-lower control arm bolts.
6. Insert pry bar between transaxle case and drive axle shaft. Pry drive axle shaft from transaxle. Pull drive
axle shaft assembly from transaxle and support shaft assembly from body with wire. Plug shaft openings
in transaxle.
7. Install engine hoist and raise engine slightly. Remove front engine support bar from engine. Disconnect
rear engine support bar from crossmember. Remove front engine mounting bolts and mounting bracket.
8. Remove caps from inside left fender shield and remove transmission mount strut bolts. Remove transaxle
mounting bracket bolts located near right strut assembly. Remove engine/transaxle assembly from vehicle
while pushing transaxle side downward during removal.
CAUTION: Replace drive axle shaft retainer rings whenever drive shafts are removed
from transaxle.
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1994 Hyundai Scoupe
Installation
To install, reverse removal procedure. With engine installed, loosely install front engine support bar bolts.
Perform final tightening of mounting bolts and nuts with weight of engine on insulators. Replace all fluids, and
adjust all control cables and linkages.
INTAKE MANIFOLD
CAUTION: Release fuel pressure before disconnecting fuel lines. See FUEL
PRESSURE RELEASE.
Removal & Installation
1. Remove idle speed actuator. Remove air intake hose connected to throttle body. (On turbo, remove intake
pipe connected to turbo charger). Remove accelerator cable. Remove water hose and throttle body.
NOTE: Label all wiring, hoses, cables and brackets before removal.
2. Remove PCV hose and brake booster vacuum hoses. Disconnect vacuum hose connections. Disconnect
high pressure fuel hose. Remove plenum stay. Remove plenum assembly and gasket. Disconnect fuel
injector harness connector.
CAUTION: DO NOT drop injectors when removing delivery pipe.
3. Remove delivery pipe with fuel injectors and pressure regulator attached. Remove insulator from intake
manifold and disconnect heater hose. Remove intake manifold. To install, reverse removal procedure.
TURBO CHARGER
Remove air intake pipe and air intake hose. Remove water feed and return hose. Disconnect oil feed and oil
drain connector hoses. Remove turbo charger discharge pipe and discharge pipe bracket. Remove turbo charger-
to-exhaust manifold bolt. Remove turbo charger as an assembly. To install, reverse removal procedure.
EXHAUST MANIFOLD
Removal
Disconnect exhaust pipe from manifold. Remove exhaust manifold outer heat shield, oxygen sensor and engine
hanger (if equipped). Remove manifold bolts, manifold, gasket and manifold inner heat shield.
Installation
To install, reverse removal procedure using NEW gaskets. Install NEW exhaust pipe-to-manifold nuts.
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1994 Hyundai Scoupe
CYLINDER HEAD
Removal
1. Drain coolant and remove upper radiator hose. Remove breather hose (between air cleaner and rocker
cover). Remove air intake pipe (turbo) and air intake hose.
2. Remove vacuum hose, fuel hose and water hose. Remove cables from spark plugs. (Remove spark plug
cables by pulling on boot.) Remove distributor. Remove intake plenum. Remove intake manifold.
3. Remove heat protector and exhaust manifold assembly. Remove water pump pulley and crankshaft
pulley.
4. Remove timing belt cover. Move timing belt tensioner pulley toward water pump and temporarily secure
it. Remove timing belt.
5. Remove rocker cover. Remove cylinder head bolts in proper sequence, using Cylinder Head Bolt Wrench
(09221-11001). Remove gasket pieces from cylinder block top surface and cylinder head bottom surface.
See Fig. 1 .
CAUTION: Ensure gasket pieces DO NOT fall into engine.
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1994 Hyundai Scoupe
Fig. 1: Loosening Cylinder Head Bolts

Courtesy of HYUNDAI MOTOR CO.
Installation
1. Install cylinder head using NEW gasket. DO NOT apply sealant to head gasket. Tighten bolts to
specification in proper sequence. See Fig. 2 . See TORQUE SPECIFICATIONS table.
2. Install timing belt in original location on camshaft sprocket. Ensure all timing marks are aligned, and
adjust timing belt. See TIMING BELT. To install remaining components, reverse removal procedure.
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1994 Hyundai Scoupe
Fig. 2: Tightening Cylinder Head Bolts

FRONT COVER OIL SEAL
See OIL PUMP under ENGINE OILING.
TIMING BELT
Removal
1. Loosen water pump pulley bolt. Loosen alternator bolt. Remove water pump pulley and belt. Remove
crankshaft pulley. Remove timing belt cover.
2. Align timing marks. Move timing belt tensioner pulley toward water pump and temporarily secure.
Remove timing belt from camshaft sprocket. Remove camshaft sprocket. Remove timing belt. See Fig.
3.
3. Remove crankshaft sprocket bolts. remove crankshaft sprocket and flange. Remove timing belt tensioner.
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1994 Hyundai Scoupe
CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place

reference mark on belt to indicate direction of rotation before removal.
Fig. 3: Aligning Timing Marks

Inspection
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1994 Hyundai Scoupe
Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner
for signs of grease leakage or roughness in tensioner rotation. Replace components if damaged.
Installation
1. Install flange on crankshaft with chamfered edge facing away from cylinder block (toward front of
engine). Install camshaft sprocket and tighten bolt to specification. See TORQUE SPECIFICATIONS
TABLE at the end of this article.
2. Align timing marks of camshaft sprocket and crankshaft sprocket, with piston No. 1 at TDC on
compression stroke. See Fig. 3 .
3. Install belt tensioner, tension spring and spacer. Ensure spring is properly engaged against front case.
Rotate tensioner toward water pump, and temporarily tighten bolts. Rotate camshaft and crankshaft, and
align all timing marks. See Fig. 3 .
4. Install timing belt on crankshaft. Ensure belt is installed in original direction of rotation. Apply pressure
on tension side of belt while installing belt on camshaft sprocket. See Fig. 4 .
5. Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all
timing marks are aligned. Temporarily install crankshaft pulley to retain timing belt.
6. Loosen timing belt tensioner bolts on belt tensioner to place tension on timing belt. See Fig. 4 . Tighten
timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this
article.
CAUTION: Slot-side timing belt tensioner bolt must be tightened before pivot-
side to prevent belt tensioner from rotating, causing belt to be
overtightened.
7. Rotate crankshaft clockwise at a constant speed for one full revolution. Loosen pivot-side bolt and then
slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specification.
8. To check belt tension, hold belt tensioner and timing belt together and apply slight thumb pressure at
center point of belt tensioner. See Fig. 4 . Ensure belt cog will reach half the width of timing belt
tensioner bolt on slot-side of belt tensioner. To install remaining components, reverse removal procedure.
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Fig. 4: Checking Timing Belt Tension

ROCKER ARM SHAFT ASSEMBLY
Removal
Remove air intake pipe. (Turbo charger only.) Remove breather hose and secondary air hose. Remove timing
belt cover and rocker cover. Loosen rocker arm shaft retaining bolts evenly in small increments, and remove
shaft assemblies.
Inspection
Check rocker arm cam contact face. If worn or damaged, replace rocker arm. Check valve cap face (valve stem
contact). If badly worn, replace valve cap. Check rocker arm shafts for damage. Replace as necessary. See Fig.
5.
Installation
To install, reverse removal procedure. Tighten rocker arm shaft assembly retaining bolts to specification. See
TORQUE SPECIFICATIONS TABLE at the end of this article. Adjust valve clearance. See VALVE
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CLEARANCE ADJUSTMENT under ADJUSTMENTS.
NOTE: When installing rocker arms note exhaust side needs "A" type only and inlet
side uses both "A" and "B" type. See Fig. 5 .
Fig. 5: Identifying Rocker Shaft Assembly

CAMSHAFT
Removal
Remove rocker arms and shafts. See ROCKER ARM SHAFT ASSEMBLY. Remove timing belt and camshaft
sprocket. See TIMING BELT. Remove distributor. Remove camshaft bearing caps. Remove camshaft.
Inspection
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1994 Hyundai Scoupe
Inspect camshaft journal diameter and lobe height for signs of wear. Replace camshaft if not within
specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Check bearing surfaces and replace
bearing caps or cylinder head as necessary. Check camshaft oil seal lips for wear and replace as necessary.
Check oil seal contact surface on cam and replace cam if worn in stages.
Installation
1. To install, coat journals with engine oil and reverse removal procedure. With camshaft installed, coat
camshaft seal contact surface with engine oil. Using Seal Installer (09222-22000), install camshaft oil
seal. See Fig. 6 .
2. To install remaining components, reverse removal procedure. Adjust valve clearance. See VALVE
CLEARANCE ADJUSTMENT under ADJUSTMENTS. After warming engine to normal running
temperature, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under
ADJUSTMENTS.
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1994 Hyundai Scoupe
Fig. 6: Installing Camshaft Oil Seal

REAR CRANKSHAFT OIL SEAL
Removal
Remove flywheel or drive plate. Remove oil seal case from rear of cylinder block. It may be necessary to
remove oil pan. Remove oil seal from seal case.
Installation
Using Seal Installer (09231-11000), install oil seal. Install oil seal and case with NEW gasket. To install
remaining components, reverse removal procedure.
WATER PUMP
CAUTION: Note bolt length and location during removal. Different length bolts are
used and must be installed in original location.
Removal
Drain cooling system and disconnect battery. Remove necessary coolant hoses. Remove timing belt. See
TIMING BELT. Remove pump mounting bolts. Note bolt length and location. Remove alternator brace and
water pump.
Installation
To install, reverse removal procedure using NEW gasket and "O" ring. Install "O" ring on coolant pipe and then
apply water to "O" ring. DO NOT apply grease or oil to "O" ring. Ensure bolts are installed in original location.
OIL PAN
Drain engine oil. Remove oil pan retaining bolts. Using gasket cutter, cut gasket along sealing surface of
cylinder block. Remove oil pan and gasket. To install, reverse removal procedure. Apply a .16" (4.1 mm) bead
of sealant to groove areas in oil pan sealing surfaces before installation.
OVERHAUL
CYLINDER HEAD
Cylinder Head
Check for cracks, damage and coolant leakage. Remove scale, sealing compound and carbon deposits. Clean oil
passages and blow compressed air through passages to ensure they are not clogged. Check EGR passage for
clogging. Inspect cylinder head for warpage at deck surface. Resurface cylinder head if warpage exceeds
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specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Springs
Inspect valve spring free length, tension and installed height. Using a square, check squareness of each spring.
Replace if not within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Installed spring height is measured from spring seat to valve retainer. Install all valve
springs with painted area toward rocker arm.
Valve Stem Oil Seals
Use Valve Seal Installer (09222-22000) for seal installation to provide proper positioning of oil seal.
Valve Guides
1. Ensure valve stem diameter and clearance are within specifications. See VALVES & VALVE SPRINGS
and CYLINDER HEAD tables under ENGINE SPECIFICATIONS.
2. If clearance exceeds service limits, valve guide can be replaced with an oversized valve guide. See
OVERSIZED VALVE GUIDE SPECIFICATIONS table.
CAUTION: Measure valve guide installed height before removal. Intake valve
guides are shorter than exhaust valve guides.
3. Use valve guide remover/installer to drive valve guide out toward cylinder block area of cylinder head.
Machine cylinder head valve guide bore to specification for oversized valve guide. See OVERSIZED
VALVE GUIDE SPECIFICATIONS table.
4. Using valve guide installer, press new guides into cylinder head from top. Install proper length valve
guide to original height of .3496-3512" (8.88-8.92 mm). Intake valve guides are shorter than exhaust
valve guides.
CAUTION: DO NOT install valve guide with same O.D. as removed guide.
5. Check guide clearance with new valve and ream as necessary. Check valve seat contact.
OVERSIZED VALVE GUIDE SPECIFICATIONS

Size Mark Guide Size - In. (mm) Cyl. Head Bore - In. (mm)
5 .002 (.05) .4350-.4354 (11.050-11.058)
25 .010 (.25) .4429-.4432 (11.250-11.258)
50 .020 (.50) .4528-.4531 (11.500-11.508)
Valve Seats
1. To replace valve seats, cut valve seat to designated dimension. Machine cylinder head to proper
dimension. See OVERSIZED VALVE SEAT SPECIFICATIONS table.
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1994 Hyundai Scoupe
2. Heat cylinder head to 482°F (250°C) and press replacement seat into cylinder head. Valve seat height
should be within specification. See OVERSIZED VALVE SEAT SPECIFICATIONS table. Cut valve
seat to proper angle and obtain correct seat width.
OVERSIZED VALVE SEAT SPECIFICATIONS

Size Mark Seat Size - In. (mm) Cyl. Head Bore - In. (mm) Seat Height - In. (mm)
Int. Valve
30 .012 (.30) 1.134-1.135 (28.80-28.82) .201-.209 (5.1-5.3)
60 .024 (.60) 1.456-1.1465 (29.100-29.121) .213-.220 (5.4-5.6)
Exh. Valve
30 .012 (.30) 1.350-1.351 (34.3-34.325) .232-.240 (5.9-6.1)
60 .024 (.60) 1.362-1.363 (34.6-34.625) .244-.252 (6.2-6.4)
Valves
Inspect each valve for wear, damage and head/stem distortion. If stem end is pitted or worn, resurface as
necessary. Keep resurfacing to a minimum. Resurface valve face. If valve margin has decreased to less than
service limit, replace valve. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
VALVE TRAIN
Rocker Arm Shaft Assembly
1. Note location of components for reassembly. Remove rocker arm shaft assembly. See ROCKER ARM
SHAFT ASSEMBLY under REMOVAL & INSTALLATION. Remove bolts, rocker arms and rocker
arm shaft springs from rocker arm shaft.
2. Reverse removal procedure and install components in original location. See Fig. 5 .
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Piston must be installed in cylinder block with front mark on top of piston toward timing belt. Note position of
connecting rod on piston before removal.
Fitting Pistons & Rings
Ensure ring end gap and side clearance are within specifications. See PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS. Properly position ring gaps before installation. See Fig. 7 .
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Fig. 7: Positioning Piston Ring Gaps

Piston Pin Replacement
Note piston location before removing piston from connecting rod. Fitting piston pin in connecting rod requires
use of proper force during installation. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Manufacturer recommends using Piston Pin Remover/Installer Kit (09234-33001) for
piston pin removal and installation. See application chart in kit for selection of pin installation depth guides, etc.
CAUTION: DO NOT exceed 5000 lbs. (2268 kg.) of force at any time during removal or
installation of piston pin.
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Crankshaft & Main Bearings
Install main bearing caps with arrow on top of cap pointing toward crankshaft pulley and in numerical sequence
according to cap number stamped near arrow. Tighten main bearing caps in 2 steps to specification, starting at
center and working outward. See TORQUE SPECIFICATIONS TABLE at the end of this article.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
A crankshaft-driven oil pump is mounted in timing cover.
Crankcase Capacity
Oil capacity with oil filter is 3.48 qts. (3.3L).
Oil Pressure
Normal oil pressure is at least 21.33 psi (1.5 kg/cm2 ) at curb idle with oil temperature of 167-203°F (75-95°C).
OIL PUMP
Removal
Remove timing belt and crankshaft sprocket. See TIMING BELT under REMOVAL & INSTALLATION.
Remove oil filter, oil pan and oil screen. Remove front cover and oil pump assembly.
Disassembly & Inspection
1. Remove rear cover. Note gear position, and mark direction of gear for reassembly reference.
2. Check outer gear-to-cover clearance. Check inner gear-to-outer gear clearance. Place straightedge across
front cover housing and measure gear end play clearance between each gear and straightedge. See Fig. 8 .
3. Ensure pressure relief valve moves freely in bore. Check relief spring tension and free length. Replace
components if not within specification. See OIL PUMP SPECIFICATIONS table.
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Fig. 8: Measuring Oil Pump

OIL PUMP SPECIFICATIONS

Application Specification
Gear End Play .0016-.0034" (.040-.087 mm)
Inner Gear-To-Outer Gear .001-.003" (.25-.069 mm)
Outer Gear-To-Case .005-.007" (.12-.18 mm)
Relief Valve Spring
Free Length 1.835" (46.60 mm)
Spring Pressure 21.4 lbs @ 1.4291" (9.7 kg @ 36.3 mm)
Reassembly & Installation
1. Install oil pump rear cover. Install oil pump and gasket assembly onto engine block. Coat outer surface of
Seal Guide (9231-22100) with oil, and install seal guide over end of crankshaft.
2. Using Seal Installer (09231-22000), install seal into front cover. Install proper length bolts and tighten to
specification. See Fig. 9 . See TORQUE SPECIFICATIONS TABLE at the end of this article.
3. Using plug cap wrench, install plug cap and tighten to specification. See TORQUE SPECIFICATIONS
TABLE at the end of this article. To install remaining components, reverse removal procedure.
PRESSURE RELIEF VALVE
NOTE: Pressure relief valve is nonadjustable and is located in front cover.
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Fig. 9: Installing Front Cover Bolts

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Camshaft Sprocket Bolt 59-74 (80-100)
Connecting Rod Cap Nut 26-28 (35-38)
Crankshaft Pulley-To-Sprocket Bolt 9.6-10.3 (13-14)
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Crankshaft Sprocket Bolt 140-148 (190-200)

Cylinder Head Bolt (1)
Cold Engine 52-55 (70-75)
Hot Engine 59-63 (80-85)
Drain Plug 26-33 (35-45)
Drive Plate-To-Crankshaft Bolt 96-103 (130-140)
Exhaust Manifold-To-Engine Bolt
Non-Turbo 11-15 (15-20)
Turbo 18-26 (25-35)
Exhaust Pipe-To-Manifold Bolt 22-30 (30-40)
Flywheel-To-Crankshaft Bolt 96-103 (130-140)
Front Cover Bolt 9-11 (12-15)
Intake Manifold Bolt 11-15 (15-20)
Intake Manifold Brace Bolt 13-18 (18-25)
Main Bearing Cap Bolt 41-44 (55-60)
Oil Pressure Switch 9.6-11 (13-15)
Oil Pump Cover Bolt 9-11 (12-15)
Oil Pump Relief Valve Plug Cap 30-37 (40-50)
Oil Screen Bolt 11-24 (15-33)
Rocker Arm Adjusting Screw Lock Nut 9-13 (12-18)
Rocker Arm Shaft Assembly Retaining Bolt 15-20 (20-27)
Sensor Wheel 9-11 (12-15)
Throttle Body-To-Intake Manifold Bolt 11-15 (15-20)
Timing Belt Tensioner Bolt 15-20 (20-27)
Torque Converter-To-Drive Plate Bolt 7-10 (9-14)
Water Pump Pulley Bolt 9-11 (12-15)
INCH Lbs. (N.m)
Oil Pan Bolt 53-71 (6-8)
Rocker Cover Bolt 13-18 (1.5-2)
Timing Belt Cover Bolt 89-106 (10-12)
(1) Tighten in sequence. See Fig. 2 .
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Displacement 89.6 Cu. In. (1.495L)
Bore 2.97" (75.5 mm)
Stroke 3.29" (83.5 mm)
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Compression Ratio
Non-Turbo 10.0:1
Turbo 7.5:1
Fuel System PFI
Turbo Unit Garrett T15
HP @ RPM
Non-Turbo 92 @ 5500
Turbo 115 @ 5500
Torque Ft. Lbs. @ RPM
Non-Turbo 97 @ 4500
Turbo 123 @ 4000
CRANKSHAFT, MAIN & CONNECTING
ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft
End Play .002-.007 (.05-.18)
Runout (Maximum) .0012 (.030)
Main Bearings
Journal Diameter 1.9685 (50.0)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance .0013-.0022 (.032-.056)
Connecting Rod Bearings
Journal Diameter 1.7717 (45.0)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance .0010-.0022 (.026-.056)
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Side Play .004-.010 (.100-.250)
PISTONS, PINS & RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

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Pistons
Clearance
Non-Turbo .0008-.0016 (.020-.040)
Turbo .0010-.0018 (.025-.045)
Diameter 2.9713-2.9724 (75.470-75.500)
Bowl Depth
Non-Turbo .012-.020 (0.3-0.5)
Turbo .240-.248 (6.1-6.3)
Pins
Piston Fit Slip Fit
Rod Fit (1) Press Fit
Rings
No. 1
End Gap .012-.020 (.30-.50)
Side Clearance .0016-.0031 (.040-.080)
No. 2
End Gap .012-.020 (.30-.50)
Side Clearance .0016-.0031 (.040-.080)
No. 3 (Oil)
End Gap .010-.039 (0.25-1.00)
(1) Press fit using 1100-3300 lbs. (499-1497 kg). DO NOT exceed 5000 lbs. (2268 kg).
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
Cylinder Bore
Standard Diameter 2.9724-2.9736 (75.500-75.530)
Maximum Taper .0004 (.010)
Maximum Out-Of-Round .0004 (.010)
Maximum Deck Warpage .002 (.05)
VALVES & VALVE SPRINGS SPECIFICATIONS
VALVES & VALVE SPRINGS

Intake Valves
Face Angle 45°
Minimum Margin .043" (1.10 mm)
Stem Diameter .236" (6.0 mm)
Exhaust Valves
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Face Angle 45°

Minimum Margin .059" (1.50 mm)
Stem Diameter .236" (6.0 mm)
Valve Springs
Free Length 1.575" (40 mm)
Installed Height 1.2598" (32.00 mm)
Out-Of-Square (Max) 1.5°
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed 44 @ 1.2598 (20 @ 32)
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Maximum Warpage .002" (.05 mm)
Valve Seats
Intake Valve
Seat Angle 45°
Seat Width .059-.067" (1.50-1.70 mm)
Exhaust Valve
Seat Angle 45°
Seat Width .043-.059" (1.10-1.50 mm)
Valve Guides
Intake Valve
Valve Guide Length 1.68" (42.7 mm)
Valve Guide Installed Height .3496-.3512" (8.88-8.92 mm)
Valve Stem-To-Guide
Oil Clearance (1) .0012-.0024" (.030-.060 mm)
Exhaust Valve
Valve Guide Length 1.54" (39.1 mm)
Valve Guide Installed Height .3496-.3512" (8.88-8.92 mm)
Valve Stem-To-Guide
Oil Clearance (2) .0020-.0031" (.050-.080 mm)
(1) Limit is .004" (.10 mm).
(2) Limit is .020" (.50 mm).
CAMSHAFT SPECIFICATIONS
CAMSHAFT
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End Play Not Furnished By Manufacturer
Lobe Height
Intake
Non-Turbo 1.61746 (41.0837)
Turbo 1.62475 (41.2689)
Exhaust 1.62475 (41.2689)
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Brenicscope 94

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1994 Hyundai Scoupe

1.5L 4-CYL - VIN [N] 1994 HYUNDAI ENGINES 1.5L 4-Cylinder

1.5L 4-CYL - VIN [N]

1994 HYUNDAI ENGINES 1.5L 4-Cylinder

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

VALVE CLEARANCE SPECIFICATIONS

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

WARNING: Relieve fuel pressure before disconnecting any fuel injection-related

Removal & Installation

CAUTION: DO NOT drop injectors when removing delivery pipe.

Removal & Installation

CAUTION: Ensure gasket pieces DO NOT fall into engine.

Fig. 1: Loosening Cylinder Head Bolts

Fig. 2: Tightening Cylinder Head Bolts

FRONT COVER OIL SEAL

See OIL PUMP under ENGINE OILING.

CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place

Fig. 3: Aligning Timing Marks

Fig. 4: Checking Timing Belt Tension

ROCKER ARM SHAFT ASSEMBLY

CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Fig. 5: Identifying Rocker Shaft Assembly

Fig. 6: Installing Camshaft Oil Seal

REAR CRANKSHAFT OIL SEAL

Removal & Installation

specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

OVERSIZED VALVE GUIDE SPECIFICATIONS

OVERSIZED VALVE SEAT SPECIFICATIONS

Rocker Arm Shaft Assembly

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

Fitting Pistons & Rings

Fig. 7: Positioning Piston Ring Gaps

Piston Pin Replacement

Crankshaft & Main Bearings

ENGINE LUBRICATION SYSTEM

A crankshaft-driven oil pump is mounted in timing cover.

Oil capacity with oil filter is 3.48 qts. (3.3L).

Disassembly & Inspection

Fig. 8: Measuring Oil Pump

OIL PUMP SPECIFICATIONS

Reassembly & Installation

PRESSURE RELIEF VALVE

NOTE: Pressure relief valve is nonadjustable and is located in front cover.

Fig. 9: Installing Front Cover Bolts

Crankshaft Sprocket Bolt 140-148 (190-200)

GENERAL ENGINE SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING

ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS