Hyundai Genesis 2009 2013 User Manual

GENESIS COUPE(BK) > 2010 > G 2.0 DOHC > General Information

General Information > General Information > General Information

Identification Number Locations

Identification Number Description

Vehicle Identification Numbe

r

1. World Manufacturer Identifier (WMI)

- KMF : Commercial vehicle (Van)

- KMH : Passenger vehicle or MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational Vehicle)

- KMJ : Van

- KM8 : MPV/SUV/RV (For U.S.A, Canada, Mexico)

2. Vehicle line

- H : GENESIS COUPE

3. Model & Series

- L : Low grade (L)

- M : Middle-Low grade (GL)

- N : Middle grade (GLS, JSL, TAX)

- P : Middle-High grade (GDS)

- R : High grade (HGS, TOP)

4. Body/Cabin type, Gross Vehicle Weight Rating
KMF (Commercial vehicle / Van)
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China

- X : Standard Cabin / Semi-Bonnet

- Y : Double Cabin / Bonnet

- Z : Super Cabin / Box
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China

- 3 : Standard Cabin Class-E 4×2 / Semi-Bonnet Class-E 4×2

- 4 : Standard Cabin Class-E 4×4 / Semi-Bonnet Class-E 4×4

- 5 : Standard Cabin Class-F 4×2 / Semi-Bonnet Class-F 4×2

- 6 : Standard Cabin Class-F 4×4 / Semi-Bonnet Class-F 4×4

- 7 : Double Cabin Class-E 4×2 / Bonnet Class-E 4×2

- 8 : Double Cabin Class-E 4×4 / Bonnet Class-E 4×4

- 9 : Double Cabin Class-F 4×2 / Bonnet Class-F 4×2

- 0 : Double Cabin Class-F 4×4 / Bonnet Class-F 4×4

- A : Super Cabin Class-E 4×2 / Box Class-E 4×2

- B : Super Cabin Class-E 4×4 / Box Class-E 4×4

- C : Super Cabin Class-F 4×2 / Box Class-F 4×2

- D : Super Cabin Class-F 4×4 / Box Class-F 4×4
KMH

- 1 : Limousine

- 2 : Sedan - 2 door

- 3 : Sedan - 3 door

- 4 : Sedan - 4 door

- 5 : Sedan - 5 door

- 6 : Coupe

- 7 : Convertible

- 8 : Wagon

- 9 : Commercial Van

- 0 : Pick-Up
KMJ

- 1 : Box

- 2 : Bonnet

- 3 : Semi-Bonnet
KM8

- 1 : Wagon 4×2 Class-A

- 2 : Wagon 4×2 Class-B

- 3 : Wagon 4×2 Class-C

- 4 : Wagon 4×2 Class-D

- 5 : Wagon 4×2 Class-E

- 6 : Wagon 4×2 Class-F

- 7 : Wagon 4×2 Class-G

- A : Wagon 4×4 Class-A

- B : Wagon 4×4 Class-B

- C : Wagon 4×4 Class-C

- D : Wagon 4×4 Class-D

- E : Wagon 4×4 Class-E

- F : Wagon 4×4 Class-F

- G : Wagon 4×4 Class-G

5. Restraint system, Brake system
KMH, KM8
Except U.S.A, Canada, Mexico

- 0 : Both side - None

- 1 : Both side - Active belt

- 2 : Both side - Passive belt
For U.S.A, Canada, Mexico

KMJ
Except U.S.A, Canada, Mexico

- 7 : Hydraulic brake system

- 8 : Pneumatic brake system

- 9 : Mixed brake system
For U.S.A, Canada, Mexico

- X : Hydraulic brake system

- Y : Pneumatic brake system

- Z : Mixed brake system
KMF
Except U.S.A, Canada, Mexico

- 7 : Hydraulic brake system

- 8 : Pneumatic brake system

- 9 : Mixed brake system
For U.S.A, Canada, Mexico

Code Sea belt

Front air bag Knee air bag Side air bag Curtain air bag

Driver's Passenger's Driver's Passenger's 1st row 2nd row 3rd row 1st row 2nd row 3rd row

A żż ż × × ż × × żż ×

B żż ż × × × × × × × ×

C żż ż × × ż × × żżż

D żż ż × × żż × żż ×

E żż × × × × × × × × ×

F żż ż × × ż × × × × ×

N ż × × × × × × × × × ×

Code

Restraint system Brake system

Sea

belt

Front air bag Knee air bag Side air bag Curtain air bag

Hydrauric Pneumatic Mixed

Driver's Passenger's Driver's Passenger's

1st

row

2nd
row

3rd

row

1st

row

2nd
row

3rd

row

X ż × × × × × × × × × × ż - -

V żż × × × × × × × × × ż - -

W żż ż × × × × × × × × ż - -

6. Engine type

- D : Gasoline engine 2.0

- H : Gasoline engine 3.8

7. Check digit or Driver’s side & Transmission
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen

Paint Code

- A : LHD & MT

- B : LHD & AT

- C : LHD & MT+Transfer

- D : LHD & AT+Transfer

- E : LHD & CVT

- L : RHD & MT

- M : RHD & AT

- N : RHD & MT+Transfer

- S : RHD & AT+Transfer

- T : RHD & CVT
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen

- Check digit : 0 ~ 9, ×

8. Production year

- A : 2010, B : 2011, C : 2012, D : 2013 …

9. Plant of production

- A : Asan (Korea)

- C : Cheonju (Korea)

- U : Ulsan (Korea)

10. Vehicle production sequence number

- 000001 ~ 999999

Code Color

NAA Ceramic White

NBA Space Black

NCA Sleek Silver

NDA Gray Titanum

NEA Blue Diamond

NFA Dynamic Yellow

NGA Super Red

NHA Blue Sapphire

NJA Lime Green

Engine Numbe

r

1. Engine fuel

- G : Gasoline

2. Engine range

- 4 : 4 cycle 4 cylinder

- 6 : 4 cycle 6 cylinder

3. Engine development order

- D : Lamda engine

- K : Theta engine

4. Engine capacity

- A : Lamda 3778 cc

- D : Theta - 2, 1998 cc

5. Production year

- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …

6. Engine production sequence number

- 000001 ~ 999999

Transaxle Numbe

r

Automatic

1. Model

- X : A5SR1

2. Production year

- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …

3. Vehicle Line

- K : BK

4. Detailed chassification

- T2 : Theta 2.0 TCI

5. Spare

6. Transaxle production sequence number

- 000001 ~ 999999

Warning / Caution Label Locations

1. Radiator Cap Caution

2. Battery Caution

3. Fan Caution

4. Coolant Level Caution

Warning / Caution Label (Cont'd)

Battery Caution Label Describtion

A.
Keep lighted cigarettes and all other flames or sparks away from the battery.

B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space.

• When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a battery carrier
or with your hands on opposite corners.

• Never attempt to change the battery when the battery cables are connected.

• The electrical ignition system works with high voltage.
Never touch these components with the engine running or the ignition switched on.

C.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery
acid to contact your skin, eyes, clothing or paint finish.

D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical
attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get medical
attention immediately.

E.
Always read the following instructions carefully when handing a battery.

F.
Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.

G.
An improperly disposed battery can be harmful to the environment and human health.
Always confirm local regurations for battery disposal.

Handling And Storage The Battery

Battery Itself

• Batteries should be stored in cool, dry (27 degrees Celsius) places and out of direct
sunlight.

• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to leak through
the vents on the sides. Therefore, batteries should always be stored in their upright
positions. Prevent placing any aqueous or solid (i.e. conductors) bodies on top of the
battery.

• It is extremely dangerous to use tools, such as hammers, on the battery terminals
when connecting cables to the mounted battery.

Battery on Vehicle

• When storing the vehicle for long periods of time, make sure to remove the memory
fuse at junction box to prevent natural discharging.

• Also, run the engine for battery charging within 1 month if the memory fuse wasn't
removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging within 3 months
from the start of vehicle storing.

After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)

Lift And Support Points

When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed, place
additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the vehicle, the
center of gravity may change and cam cause the vehicle to tip forward on the hoist.

• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage area can
assist with the weight distribution.

• Use the same support points to support the vehicle on safety stands.

1. Place the lift blocks under the support points as shown in the illustration.

2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very
dangerous.

There are three popular methods of towing a vehicle :

If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the drivig axle off the ground and do the
following :
Manual Transaxle

A

utomatic Transaxle

Towing

Emergency Towing

- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.

- The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. the other two
wheels remain on the ground.

- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and the
cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method
of towing is attempted.

• Release the parking brake.

• Shift the Transaxle to neutral

• Release the parking brake.

• Start the engine.

• Shift to [D] position, then [N] position.

• Turn off the engine.

• The vehicle equipped with full-time 4WD should be only transported on a flat-bed.

• Improper towing preparation will damage the transaxle. follow the above procedure exactly. If you cannot shift the
transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed.

• It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph). (For the full­time 4WD vehicle, limit the towing to 1.5km (1mile) and 15km/h (10mph)

• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed to
support the vehicle's weight.

Front :

Rear :

Tightening Torque Table Of Standard Parts

Bolt niminal diameter

(mm)

Pich (mm)

Torque Nm (kg.cm, lb.ft)

Head Mark 4 Head Mark 7

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)

M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )

M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)

M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)

M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~

Protection Of The Vehicle

A

lways be sure to cover fenders, seats, and floor areas before starting work.

Be sure that all necessary tools and measuring equipment are available starting work.

Use special tools when they are required.

100)

M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~ 94) 180 ~ 210 (1,800 ~ 2,100, 130 ~

150)

M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116 ~

130)

260 ~ 300 (2,600 ~ 3,000, 190 ~

215)

M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160 ~

180)

360 ~ 420 (3,600 ~ 4,200, 260 ~

300)

M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210 ~

240)

480 ~ 550 (4,800 ~ 5,500, 350 ~

400)

M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260 ~

300)

610 ~ 700 (6,100 ~ 7,000, 440 ~

505)

- The torques shown in the table are standard values under the following conditions :

• Nuts and bolts are made of galvanized steel bar.

• Galvanized plain steel washers are inserted.

• All nuts, bolts and plain washers are dry.

- The torques shown in the table are not applicable :

• When spring washers, toothed washers and the like are inserted.

• If plastic parts are fastened.

• If self-tapping screws or self-locking nuts are used.

• If threads and surfaces are coated with oil.

- If you reduce the torques in the table to the percentage indicated below, under the following conditions, if will be the
standard value.

• If spring washers are used : 85%

• If threads and bearing surfaces are stained with oil : 85%

General Service Information

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to
prevent the hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is firmly
latched before driving the vehicle.

Preparation Of Tools And Mesuring Equipment

Special Tools

First find the cause of the problem and then determine whether removal or disassembly before starting the job.

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way
that will not affect their performance or external appearance.

Removal Of Parts

Disassembly

1. Inspection of parts

Each part, when removed, should be carefully on suspected for malfunction, deformation, damage, and other problems.

2. Arrangement of parts

All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.

3. Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.

When replacing parts, use HYUNDAI genuine parts.

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.

Parts

Replacement

1. Oil seals

2. Gaskets

3. O-rings

4. Lock washers

5. Cotter pins (split pins)

6. Plastic nuts

Depending on their location.

7. Sealant should be applied to gaskets.

8. Oil should be applied to the moving components of parts.

Use gauges and testers to adjust correctly the parts to standard values correctly.

A

lways prevent gasoline or from touching rubber parts or tubing.

9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.

Adjustment

Electrical System

1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.

2. Never pull on the wires when disconnecting connectors.

3. Locking connectors will click when the connector is secure.

4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

Ruber Parts And Tubes

Measuring Body Dimensiongs

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this manual.

Dimensions Projected

1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the

Measurements should be taken at the center of the hole.

reference dimensions used for used for body alterations.

2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the different
value in height of the two surface.

Measuring Actual Dimensions

1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.

2. First adjust both probes to the same length (A=A') before measurement.

Check the probes and gauge itself to make sure there is no free play.

Measurement Point

A

blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is good if the
test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition
switch so that the fuse circuit becomes operative)

Checking Cables And Wires

1. Check the terminal for tightness.

2. Check terminals and wires for corrosion from battery electrolyte, etc.

3. Check terminals and wires for open circuits.

4. Check wire insulation and coating for damage, cracks and degrading.

5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's body.

7. Check for incorrect wiring.

8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust
manifold, etc.)

9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating or moving
parts.

10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and

the engine.

Check Fuses

Serivicing The Electrical System

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable.

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained
by the computer will be cleared. There fore, if necessary, read the diagnostic before removing the battery cable.

2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other
vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness
to come into contact with any of the surrounding parts and then secure the harness by using a clamp.

3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or
something similar in order to protect if from damage.

4. When installing any parts, be careful not to pinch or damage any of the wiring harness.

5. Never throw relays, sensors or electrical parts, or expose them to strong shock.

6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations
that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.

7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

8. When disconnecting a connector, be sure to grip only the connector, not the wires.

9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.

10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side.

If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal,
being careful not to damage the insulation of the wires.

12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine

the appropriate wire size.

Noeminal size SAE gauge No.

Permissible current

In engine compartment Other areas

0.3mm² AWG 22 - 5A

0.5mm² AWG 20 7A 13A

0.85mm² AWG 18 9A 17A

1.25mm² AWG 16 12A 22A

2.0mm² AWG 14 16A 30A

3.0mm² AWG 12 21A 40A

5.0mm² AWG 10 31A 54A

Precautions For Catalytic Converte

r

If a large amount of unburned gasolined gasoline flow into the converter, it may overheat and create a fire hazard. To
prevent this observe the following precations and explain them to your customer.

1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than 10minutes
and idle speed for more than 20 minutes.

3. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly as possible and, while
testing, never race the engine.

4. Do not measure engine compression for and extended time. Engine compression tests must be made as rapidly as possible.

5. Avoid coasting with the ignition turned and during prolonged braking.

6. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > General
Information > Specifications

Specifications

Description Specifications Limit

General

Type In-line, Double Overhead Camshaft

Number of cylinder 4

Bore 86mm (3.385in)

Stroke 86mm (3.385in)

Total displacement 1998cc (121.92cu.in.)

Compression ratio 9.4 : 1

Firing order 1-3-4-2

Valve timing

Intake valve

Opens (ATDC / BTDC) ATDC 11° ~ BTDC 34°

Closes (ABDC) ABDC 67° ~ 22°

Exhaust

Opens (BBDC) BBDC 54° ~ 14°

Closes (ATDC) ATDC -10° ~ 30°

Valve

Valve length

Intake 113.18mm (4.4559in.) 112.93mm

(4.4460in)

Exhaust 105.79mm (4.1649in.) 105.59mm

(4.1570in)

Stem O.D.

Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)

Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

Face angle 45.25° ~ 45.75°

Margin

Intake 1.02mm (0.0401in.)

Exhaust 1.09mm (0.0429in.)

Valve stem to valve guide clearance

Intake 0.020 ~ 0.047mm (0.00078 ~ 0.00185in.) 0.07mm (0.00275in.)

Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.) 0.09mm (0.00354in.)

Valve guide

Length

MLA

MLA outer diameter 31.964 ~ 31.980mm (1.2584 ~ 1.2590in.)

Cylinder head tappet bore inner diameter 32.000 ~ 32.025mm (1.2598 ~ 1.2608in.)

MLA to tappet bore clearance 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm (0.0027in.)

Valve seat

Width of seat contact

Intake 1.16 ~ 1.46mm (0.0457 ~ 0.0575in.)

Exhaust 1.35 ~ 1.65mm (0.0531 ~ 0.0649in.)

Seat angle 44.75° ~ 45.10°

Valve guide

Length 43.8 ~ 44.2mm (1.7244 ~ 1.7401in.)

Inner diameter 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)

Valve spring

Free length 47.44mm (1.8677in.)

Load 19.0 ± 0.6kg/35.0mm (41.88 ± 1.32lb/1.3779in.)

Square 39.8 ± 1.2kg/26.0mm (87.74 ± 2.64lb/1.0236in.)

1.5° MAX.

Valve clearance

Cold (20°C[68°F])

Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) 0.10 ~ 0.30mm

(0.0039 ~ 0.0118in.)

Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in,) 0.20 ~ 0.40mm

(0.0078 ~ 0.0157in.)

Cylinder head

Flatness of gasket surface Max. 0.05mm (0.0019in.)

Flatness of manifold mounting surface Max. 0.10mm (0.0039in.)

Cylinder block

Cylinder bore 86.00 ~ 86.03mm (3.3853 ~ 3.3871in.)

Out-of-round and taper of cylinder bore Less than 0.05mm (0.0019in.)

Clearance with piston
(To set limits to new parts)

0.015 ~ 0.035mm (0.0005 ~ 0.0013in.)

Piston

O.D (To set limits to new parts) 87.975 ~ 88.005mm (3.4635 ~ 3.4647in.)

Ring groove width

No.1 1.235 ~ 1.250mm (0.0486 ~ 0.0492in.) 1.26mm (0.0496in.)

No.2 1.230 ~ 1.250mm (0.0484 ~ 0.0492in.) 1.26mm (0.0496in.)

Oil ring 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) 2.05mm (0.0807in.)

Piston ring

Side clearance

No.1 0.05 ~ 0.08mm (0.0019 ~ 0.0031in.) 0.1mm (0.004in.)

No.2 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.) 0.1mm (0.004in.)

Oil ring 0.06 ~ 0.13mm (0.0023 ~ 0.0051in.) 0.2mm (0.008in.)

End gap

No.1 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.) 0.6mm (0.0236in.)

No.2 0.37 ~ 0.52mm (0.0145 ~ 0.0204in.) 0.7mm (0.0275in.)

Oil ring side rail 0.20 ~ 0.70mm (0.0078 ~ 0.0275in.) 0.8mm (0.0315in.)

Piston pin

Piston pin outer diameter 21.997 ~ 22.000mm (0.8660 ~ 0.8661in.)

Piston pin hole inner diameter 22.030 ~ 22.070mm (0.8673 ~ 0.8688in.)

Piston pin hole clearance 0.003 ~ 0.010mm (0.0001 ~ 0.0004in.)

Connecting rod small end inner diameter 22.005 ~ 22.011mm (0.8663 ~ 0.8666in.)

Connecting rod

Bend 0.05mm (0.0020in.) or less

Twist 0.1mm (0.004in.) or less

Connecting rod big end to crankshaft side
clearance

0.100 ~ 0.250mm (0.0039 ~ 0.010in.) 0.35mm (0.0138in.)

Connecting rod bearing

Oil clearance (To seat limits to new parts) 0.025 ~ 0.043mm (0.0009 ~ 0.0016in.) 0.05mm ( 0.0078in.)

Camshaft

Cam height Intake 43.80mm (1.7244in.)

Exhaust 45.00mm (1.7716in.)

Journal O.D Intake No.1

᪮30mm (1.1811in.)

No.2, 3, 4, 5

᪮24mm (0.9449in.)

Exhaust No.1

᪮36mm (1.4173in.)

No.2, 3, 4, 5

᪮24mm (0.9449in.)

Bearing oil
clearance

Intake No.1 0.022 ~ 0.057mm (0.0008 ~ 0.0022in.) 0.09mm (0.0035in.)

No.2, 3, 4, 5 0.045 ~ 0.082mm (0.0017 ~ 0.0032in.) 0.12mm (0.0047in.)

Exhaust No.1 0 ~ 0.032mm (0 ~ 0.0012in.)

No.2, 3, 4, 5 0.045 ~ 0.082mm (0.0017 ~ 0.0032in.) 0.12mm (0.0047in.)

End play 0.04 ~ 0.16mm (0.0015 ~ 0.0062in.) 0.20mm (0.0047in.)

Crankshaft

Pin O.D. 47.954 ~ 47.972mm (1.8879 ~ 1.8886in.)

Journal O.D. 51.942 ~ 51.960mm (2.0449 ~ 2.0456in.)

End play 0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)

Crankshaft bearing

Oil clearance 0.020 ~ 0.038mm (0.0007 ~ 0.0014in.)

Cooling method Water-cooled, pressurized. Forced circulation

with water pump

Engine oil

Oil quantity

Total 5.9L (6.23US qt, 5.19lmp qt)

When replacing a
short engine or a
block assembly

Oil pan 5.0L (5.28US qt, 4.41lmp qt)

Drain and refill 5.3L (5.60US qt, 4.66lmp qt) Including oil filter

Oil grade

Classification

API SL, SM or above

ILSAC GF3, GF4 or above

Satisfy the
requirement of the
API or ILSAC
classification.

SAE viscosity grade 5W-20, 5W-30, 5W-40

Oil pressure (at 1000rpm) 127kPa (1.3kg/cm², 18.49psi) or above

Oil temperature in oil
pan : 110±2°C
(230±36°F)

Radiator

Type Pressurized corrugated fin type

Radiator cap

Main valve opening pressure 83 ~ 110kpa (12 ~ 16psi, 0.83 ~ 1.1kg/cm²)

Vacuum valve opening pressure -7kpa (-100psi, -0.07kg/cm²) or less

Thermostat

Type Wax pellet type with jiggle valve

Valve opening temperature 82°C (177°F)

Full-opening temperature 95°C (201°F)

Coolant pump Centrifugal type impeller

Drive belt

Type V-ribbed belt

Engine coolant temperature sensor

Type Heat-sensitive thermistor type

Resistance 2.31 ~ 2.59K at 20°C (68°F)

Air cleaner

Type Dry type

Element Paper type

Exhaust pipe

Muffler Expansion resonance type

Suspension system Rubber hangers

Service Standrds

Standard value

Antifreeze Mixture ratio of anti-freeze in coolant

ETHYLENE GLYCOL BASE FOR ALUMINUM 50%

Tightening Torques

Item N.m kgf.m lb-ft

Ladder frame bolt (M8 x 55) 23.5 ~ 27.4 2.4 ~ 2.8 17.4 ~ 20.2

Oil pump bolt (BSM) 8.8 + 16.6 + 25.5 0.9 + 1.7 + 2.6 6.5 + 12.3 + 18.8

Timing chain cover bolt (M8) 18.6 ~ 22.5 1.9 ~ 2.3 13.7 ~ 16.6

Timing chain cover bolt (M6) 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Oil pan bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Engine support bracket bolt (LH/RH) 49.0 ~ 63.7 5.0 ~ 6.5 36.1 ~ 47.0

Camshaft bearing cap bolt (M6) 10.8 ~ 12.7 1.1 ~ 1.3 7.9 ~ 9.4

Camshaft bearing cap bolt (M8) 27.4 ~ 31.4 2.8 ~ 3.2 20.3 ~ 23.1

Cylinder head bolt (32.4~36.3) +

(90~95°) + (90~95°)

(3.3~3.7) + (90~95°)

+ (90~95°)

(23.9~26.8) +

(90~95°) + (90~95°)

Engine hanger bolt 27.5 ~ 31.4 2.8 ~ 3.2 20.3 ~ 23.1

Cylinder head cover bolt 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Crankshaft pulley bolt 166.6 ~ 176.4 17.0 ~ 18.0 122.9 ~ 130.1

Connecting rod bearing cap bolt (17.7~21.6) +

(88~92°)

(1.8~2.2) + (88~92°) (13.0~15.9) +

(88~92°)

Main bearing cap bolt 14.7 + (27.5~31.4) +

(120~125°)

1.5 + (2.8~3.2) +
(120~125°)

10.8 + (20.3~23.1) +
(120~125°)

Flywheel bolt 117.6 ~ 127.4 12.0 ~ 13.0 86.8 ~ 93.9

Drive plate bolt 117.6 ~ 127.4 12.0 ~ 13.0 86.8 ~ 93.9

Timing chain tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain tensioner arm bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain guide bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

OCV bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

CVVT bolt 53.9 ~ 63.7 5.5 ~ 6.5 39.7 ~ 47.0

BSM chain tensioner arm bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

BSM chain guide bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

BSM chain tensioner bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Water pump bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

P/S pump bracket bolt 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4

Tensioner ASSY intergrated bracket bolt 39.2 ~ 44.1 4.0 ~ 4.5 28.9 ~ 32.5

Water temp. control nut 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Water inlet pipe nut 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Water temp. control bolt 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.4

Oil level gauge assembly bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Ignition coil bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3

Intake manifold bolt 18.6 ~ 27.4 1.9 ~ 2.8 13.7 ~ 20.2

Intake manifold nut 18.6 ~ 27.4 1.9 ~ 2.8 13.7 ~ 20.2

Intake manifold stay bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Exhaust manifold heat protector bolt 18.6 ~ 27.4 1.9 ~ 2.8 13.7 ~ 20.2

Exhaust manifold nut 49.0 ~ 53.9 5.0 ~ 5.5 36.1 ~ 39.7

Exhaust manifold stay bolt (M8) 18.6 ~ 27.4 1.9 ~ 2.8 18.6 ~ 20.2

Exhaust manifold stay bolt (M10) 49.0 ~ 53.9 5.0 ~ 5.5 36.1 ~ 39.8

Muffler bolt 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Crankshaft position sensor bolt 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3

Oxygen sensor 39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.1

Knock sensor 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8

Camshaft position sensor 3.9 ~ 5.9 0.4 ~ 0.6 2.9 ~ 4.3

Oil pressure switch 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

Oil filter 11.8 ~ 15.7 1.2 ~ 1.6 8.7 ~ 11.6

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > General
Information > Repair procedures

Compression Pressure Inspection

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.

1. Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.

2. Disconnect the injector connectors (A), ignition coil connectors (B) and ignition coils.

3. Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs.

4. Check cylinder compression pressure.

A. Insert a compression gauge into the spark plug hole.

B. Fully open the throttle.

C. While cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 200 rpm or more.

D. Repeat steps (a) through (c) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure :

1,283kPa (13.0kgf/cm², 185psi)

Minimum pressure :

1,135kPa (11.5kgf/cm², 164psi)

Difference between each cylinder :

100kPa (1.0kgf/cm², 15psi) or less

E. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder

through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.

• If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or
damaged.

• If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the
gasket.

5. Reinstall spark plugs.

6. Connect the injector connectors and ignition coil connectors.

Valve Clearance Inspection And Adjustment

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C (68°F)) and
cylinder head is installed on the cylinder block.

1. Remove the cylinder head cover. (Refer to Timing system)

2. Set No.1 cylinder to TDC/compression.
A. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.

B. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as

shown in the illustration.
If not, turn the crankshaft one revolution (360°)

3. Inspect the valve clearance.
A. Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

·Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.

·Record the out-of-specification valve clearance measurements. They will be used later to determine the
required replacement adjusting tappet.

Valve clearance

Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)

B. Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the lower timing

chain cover.

C. Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance.

4. Adjust the intake and exhaust valve clearance.
A. Set the No.1 cylinder to the TDC/compression.

B. Marks on the timing chain and camshaft timing sprockets.

C. Remove the service hole bolt(A) of the timing chain cover.

The bolt must not be reused once it has been assembled.

D. Insert the SST(A) (09240-2G000) in the service hole of the timing chain cover and release the ratchet.

E. Remove the front camshaft bearing cap(A).

F. Remove the exhaust camshaft bearing cap and exhaust camshaft.

G. Remove the intake camshaft bearing cap and intake camshaft.

When disconnect the timing chain from the camshaft timing sprocket, hold the timing chain.

H. Tie down timing chain so that it dosen't move.

Be careful not to drop anything inside timing chain cover.

I. Measure the thickness of the removed tappet using a micrometer.

J. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

Valve clearance (Engine coolant temperature : 20°C)

T : Thickness of removed tappet

A

: Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A-0.30mm (0.0118in.)]

K. Select a new tappet with a thickness as close as possible to the calculated value.

Shims are available in 47size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.690mm
(0.1452in.)

L. Place a new tappet on the cylinder head.

M. Hold the timing chain, and install the intake camshaft and timing sprocket assembly.

N. Align the matchmarks on the timing chain and camshaft timing sprocket.

O. Install the intake and exhaust camshaft.

P. Install the front bearing cap.

Q. Install the sevice hole bolt.

Tightening torque :

11.8 ~ 14.7N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8lb-ft)

R. Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and

camshaft sprocket timing marks(A).

S. Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C)

[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > General
Information > Troubleshooting

Troubleshootin

g

Symption Suspect area Remedy

Engine misfire with
abnormal internal lower
engine noises.

Worn crankshaft bearings
Loose or improperly engine filwheel

Replace the crankshaft and bearings as
required.
Repair or replace the flywheel as required.

Worn piston rings
(Oil consumption may or may not cause
the engine to misfire.)

Inspect the cylinder for a loss of compression.
Repair or replace as required.

Worn crankshaft thrust bearings

Replace the crankshaft and bearings as
required

Engine misfire with
abnormal valve train
noise.

Stuck valves.
(Carbon buidup on the valve stem)

Repair or replace as required

Excessive worn or mis-aligned timing
chain

Replace the timing chain and sprocket as
required.

Worn camshaft lobes. Replace the camshaft and valve lifters.

Engine misfire with
coolant consumption

• Faulty cylinder head gasket or other
damage to the cylinder head and
engine block cooling system.

• Coolant consumption may or may
not cause the engine to overheat.

• Inspect the cylinder head and engine block
for damage to the coolant passages and/or
a faulty head gasket.

• Repair or replace as required.

Engine misfire with
excessive oil
consumption

Worn valves, guides and/or valve stem
oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not cause
the engine to misfire)

• Inspect the cylinder for a loss of
compression.

• Repair or replace as required.

Engine noise on start­up, but only lasting a
few seconds.

Incorrect oil viscosity

• Drain the oil.

• Install the correct viscosity oil.

Worn crankshaft thrust bearing.

• Inspect the thrust bearing and crankshaft.

• Repair or replace as required.

Upper engine noise,
regardless of engine
speed.

Low oil pressure Repair or replace as required.

Broken valve spring. Replace the valve spring.

Worn or dirty valve lifters. Replace the valve lifters.

Stetched or broken timing chain and/or
damaged sprocket teeth.

Replace the timing chain and sprockets.

Worn timing chain tensioner, if
applicable.

Replace the timing chain tensioner as required.

Worn camshaft lobes.

• Inspect the camshaft lobes.

• Replace the timing camshaft and valve
lifters as required.

Worn valve guides or valve stems.

Inspect the valves and valve guides, then repair
or replace as required.

Stuck valves. (Carbon on the valve stem
or valve seat may cause the valve to

Inspect the valves and valve guides, then repair
or replace as required.

stay open.

Worn drive belt, idler, tensioner and
bearing.

Replace as required

Lower engine noise,
regardless of engine
speed

Low oil pressure Repair or required.

Loose or damaged flywheel. Repair or replace the flywheel.

Damaged oil pan, contacting the oil
pump screen.

• Inspect the oil pan.

• Inspect the oil pump screen.

• Repair or replace as required.

Oil pump screen loose, damaged or
restricted.

• Inspect the oil pump screen.

• Repair or replace as required.

Excessive piston-to-cylinder bore
clearance.

• Inspect the piston, piston pin and cylinder
bore.

• Repair or replace as required.

Excessive piston pin-to-piston clearance

• Inspect the piston, piston pin and the
connecting rod.

• Repair or replace as required.

Excessive connecting rod bearing
clearance

Inspect the following components and repair or
replace as required.

• The connecting rod bearings.

• The connecting rods.

• The crankshaft pin journals.

Excessive crankshaft bearing clearance Inspect the following components, and repair or

replace as required.

• The crankshaft bearings.

• The crankshaft main journals.

• The cylinder block

Incorrect piston, piston pin and
connecting rod installation

• Verify the piston pins and connecting rods
are installed correctly.

• Repair as required.

Engine noise under load Low oil pressure Repair or replace as required.

Excessive connecting rod bearing
clearance

Inspect the following components and repair or
replace as required :

• The connecting rod bearings.

• The connecting rods.

• The crankshaft

Excessive crankshaft bearing clearance Inspect the following components, and repair or

replace as required.

• The crankshaft bearings.

• The crankshaft main journals.

• The cylinder block.

Engine will not crank­crankshaft will not rotate

Hydraulically locked cylinder

• Coolant/antifreeze in cylinder.

• Oil in cylinder.

• Fuel in cylinder

1. Remove spark plugs and check for fluid.

2. Inspect for broken head gasket.

3. Inspect for cracked engine block or cylinder
head.

4. Inspect for a sticking fuel injector and/or
leaking fuel regulator.

Broken timing chain and/or timing chain
and/or timing chain gears.

1. Inspect timing chain and gears.

2. Repair as required.

Material in cylinder

• Broken valve

• Piston material

• Foreign material

1. Inspect cylinder for damaged components
and/or foreign materials.

2. Repair or replace as required.

Seized crankshaft or connecting rod
bearings.

1. Inspect crankshaft and connecting rod
bearing.

2. Repair as required.

Bent or broken connecting rod.

1. Inspect connecing rods.

2. Repair as required.

Broken crankshaft

1. Inspect crankshaft.

2. Repair as required.

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > General
Information > Special Service Tools

Special Service Tools

Tool (Number and name) Illustration Use

Crankshaft front oil seal installer
(09214-3K000)
(09231-H1100)

Installation of the front oil seal
A : 09214-3K000
B : 09231-H1100

Valve stem seal

Removal of the valve stem seal

Torque angle adapter
(09221-4A000)

Installtion of bolts & nuts needing an angular
method of adjustment.

Valve stem oil seal installer
(09222-4A000)

Installation of the valve stem oil seal

Valve spring compressor &
holder
(09222-3K000)
(09222-3K100)

Removal and installation of the intake or
exhaust valve
09222-3K100 (holder)

Crankshaft rear oil seal installer
(09214-3K100)
(09231-H1100)

Installation of the crankshaft rear oil seal
A : 09214-3K100
B : 09231-H1100

Timing chain tensioner ratchet
holder
(09240-2G000)

Timing chain tension release.
In vehicle inspection and adjustment of valve
clearance.

Crankshaft pulley adapter
(09231-2M100)
Crankshaft pulley adapter holder
(09231-2J210)

Removal and installation of crankshaft pulley
from the vehicle
A : 09231-2M100
B : 09231-2J210 (Holder)

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Engine And Transaxle
Assembly > Engine Mounting > Components and Components Location

Components

1. Engine mounting bracket

2. Engine support bracket RH

3. Engine support bracket LH

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Engine And
Transaxle Assembly > Engine And Transaxle Assembly > Repair procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

For release the fuel pressure, start the engine and wait until fuel in fuel line is exhausted.
After the engine stop turn the ignition switch OFF.

Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable (A).

2. Remove the transmission system before removing the engine system. (Refer to MT, AT group)

3. Remove the strut bar (B).

4. Remove the drain plug (A) and drain the engine coolant.

5. After recovering refrigerant, remove the high & low pressure pipe. (Refer to HA group)

6. Disconnect the breather hose (A), vacuum hose (B). And remove the air duct (C) and air cleaner assembly (D).

Tightening torque :

Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Clamp : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

7. Remove the radiator upper hose (A) .

8. Remove the intercooler inlet hose (A) and radiator lower hose (B).

Tightening torque :

Bolt : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.4lb-ft)
Clamp : 4.9 ~ 6.8 N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)

9. Remove the intercooler outlet hose (B) after disconnecting the BPS connector (A).

10. Remove the cooling fan.
(1) Remove the cooling fan connector (A).

(2) Remove the reservoir tank (B).

(3) Remove the fan assembly (C).

11. Disconnect the oil pressure (OPS) sensor (A) and remove the power steering oil hoses (B).

12. Disconnect the ECM connectors (A), brake oil level sensor connector (B) and ground (C).

13. Disconnect the brake booster vacuum hose (A), PCSV hose (B) and fuel hose (C).

14. Remove the alternator cable. (Refer to EE group)

15. Disconnect the the battery (+) cable (A), wirings (B) and heater hoses (C).

16. Remove the engine mounting bracket nut (A) and bolt (B).

Tightening torque :

66.7 ~ 83.4N.m (6.8 ~ 8.5kgf.m, 49.2 ~ 61.5lb-ft)

Installation is in the reverse order of removal.
Perform the following :

17. Remove the hood. (Refer to BD group)

18. Remove the engine assembly by lifting the engine jack.

When removing the engine assembly, be careful not to damage any surrounding parts or body components.

Installation

• Adjust a shift cable.

• Adjust a throttle cable.

• Refill engine with engine oil.

• Refill a transaxle with fluid.

• Refill power steering fluid.

• Refill a radiator and a reservoir tank with engine coolant.

• Place a heater control knob on "HOT" positon.

• Inspect for fuel leakage.

- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.

- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

• Bleed air from the cooling system.

- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)

- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.

- Put radiator cap on tightly, then run the engine again and check for leaks.

• Clean battery posts and cable terminals and assemble.

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Timing System > Timing
Chain > Components and Components Location

Components

1. Cylinder head cover

2. Exhaust CVVT assembly

3. Intake CVVT assembly

4. Timing chain

5. Timing chain tensioner arm

6. Timing chain tensioner guide

7. Crankshaft sprocket

8. Oil jet

9. Timing chain tensioner

10. Timing chain cover

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Timing
System > Timing Chain > Repair procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery nagative cable (A).

2. Loosen the drain plug (A) and drain the engine coolant.

3. Disconnect the breather hose (A), vacuum hose (B). And remove the air duct (C) and air cleaner assembly (D).

4. Remove the radiator upper hose (A).

5. Remove the intercooler outlet hose (B) after disconnecting the BPS connector (A).

6. Remove the intercooler inlet hose (A).

7. Disconnect the ignition coil connectors (A) and remove the ignition coils.

8. Remove the cylinder head cover (D) after removing the vacuum hoses (B) and PCV hose (C).

9. Set No.1 cylinder to TDC/compression.

10. Remove the drive belt (A), alternator (B) and power steering pump (C).

11. Remove the tensioner assembly (A), water pump assembly (B), idler (C) and crankshaft pulley (D).

Use the SST (crankshaft pulley adapter and holder, 09231-2M100,09231-2J210,) to remove the crankshaft
pulley bolt.

12. Remove the lower oil pan using the SST (09215-3C000).

• Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the
direction of arrow #1.

• After tapping the SST with a plastic hammer along the direction of arrow #2 around more than 2/3 edge
of the oil pan, remove it from the ladder frame.

• Do not turn over the SST abruptly without tapping. It be result in damage of the SST.

• Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.

13. Remove the timing chain cover (A).

Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

14. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston
of No.1 cylinder is placed at the top dead center on compression stroke.

15. Install a set pin after compressing the timing chain tensioner.

16. Remove the timing chain tensioner (A) and timing chain tensioner arm (B).

17. Remove the timing chain.

18. Remove the timing chain guide (A).

19. Remove the timing chain oil jet (A) and crankshaft sprocket (B).

20. Remove the balance shaft chain.
(Refer to Lubrication system in this group)

Inspection

Sprockets, Hydraulic Tensioner, Chain Guide, Tensioner Arm

1. Check the CVVT sprocket, crankshaft sprocket teeth for abnormal wear, cracks or damage. Replace if necessary.

2. Check a contact surface of the chain tensioner arm and guide for abnormal wear, cracks or damage. Replace if

necessary.

3. Check the hydraulic tensioner for its piston stroke and ratchet operation. Replace if necessary.

Belt, Idler, Pulley

1. Check the idler for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.

2. Check belt for maintenance and abnormal wear of V-ribbed part. Replace if necessary.

3. Check the pulleys for vibration in rotation, oil or dust deposit of V-ribbed part. Replace if necessary.

Installation

1. Install the timing chain oil jet (A) and crankshaft sprocket (B).

Tightening torque :

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

2. Set crankshaft that the key of crankshaft should be aligned with the mating surface of main bearing cap. Put the

intake, exhaust camshaft assembly that the TDC mark of intake sprocket and exhaust sprocket should be aligned
with the top surface of cylinder head. As a result of this, place the piston on No.1 cylinder at the top dead center
on compression stroke.

3. Install the timing chain guide (A).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

4. 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.

5. Install the timing chain tensioner arm (B).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

6. Install the timing chain auto tensioner (A) and remove the set pin.

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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

8. Install timing chain cover.

A. Using a gasket scraper remove all the old packing meterial from the gasket surfaces.

B. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame)

must be free of engine oil and ETC.

C. Before assembling the timing chain cover, the liquid sealant Loctite 5900H or THREEBOND 1217H should be

applied on the gap between cylinder head and cylinder block.

The part must be assembled within 5 minutes after sealant was applied.

Bead width : 2.5±0.5mm (0.098±0.019in.)

D. After applying liquid sealant Loctite 5900H on timing chain cover. The part must be assembled within 5

minutes after sealant was applied. Sealant should be applied without discontinuity.

Bead width : 3.0mm(0.12in.)

E. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in

order to assemble the timing chain cover to be in exact position.

Tightening torque :

M6 : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
M8 : 18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)

F. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was

assembled.

9. Install the oil pan.

A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.

B. Before assembling the oil pan, the liquid sealant Loctite 5900H or THREEBOND 1217H should be applied on

oil pan. The part must be assembled within 5 minutes after the sealant was applied.

• When applying sealant gasket, sealant must not be protruded into the inside of oil pan.

• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

C. Install the oil pan (A).

Uniformly tighten the bolts in several passes.

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

D. After assembly, wait at least 30 minutes before filling the engine with oil.

10. Install the cylinder head cover.

A. The hardened sealant located on the upper area between timing chain cover and cylinder head should be

removed before assembling cylinder head cover.

B. After applying sealant (Loctite 5900H), it should be assembled within 5 minutes.

Bead width : 2.5±0.5mm (0.098±0.019in.)

C. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was

assembled.

D. Install the cylinder head cover bolts as following method.

Tightening torque :

Step 1 : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Step 2 : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Do not reuse cylinder head cover gasket.

11. Install the crankshaft pulley (D).

Tightening torque :

166.7 ~ 176.5N.m (17 ~ 18kgf.m, 122.9 ~ 130.2lb-ft)

Fix the crankshaft using the SST (09231-2M000, 09231-2J210) when installing the crankshaft pulley bolt.

12. Install the water pump pulley (B) and Idler (C).

Tightening torque :

B: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
C: 53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.8 ~ 47.0lb-ft)

13. Install the tensioner bracket assembly (A).

Tightening torque :

39.2 ~ 44.1N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)

14. Install the alternator (B), power steering pump (C) and drive belt (A).

Tightening torque :

B: 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)

C: 16.6 ~ 19.6N.m (1.7 ~ 2.0kgf.m, 12.3 ~ 14.5lb-ft)

15. Install the ignition coil and connect the ignition coil connector (A).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

16. Install the vacuum hose (B) and PCV hose (C).

17. Install the intercooler inlet hose (A).

Tightening torque :

Bolt : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.4lb-ft)
Clamp : 4.9 ~ 6.8N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)

18. Install the intercooler outlet hose (B) and connect the BPS connector (A).

19. Install the radiator upper hose (A).

20. Install the air cleaner assembly (D) and air duct (C). And then connect the breather hose (A) and vacuum hose
(B).

Tightening torque :

Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Clamp : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.1 ~ 3.6lb-ft)

21. Connect the battery negative cable (A).

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Cylinder Head
Assembly > Cylinder Head > Components and Components Location

Components

1. Camshaft bearing cap

2. Camshaft front bearing cap

3. Exhaust camshaft

4. Intake camshaft

5. Exhaust CVVT assembly

6. Intake CVVT assembly

7. Exhaust camshaft upper bearing

8. Exhaust camshaft lower bearing

9. MLA

10. Retainer lock

11. Retainer

12. Valve spring

13. Valve stem seal

14. Valve

15. Cylinder head

16. Intake OCV

17. Exhaust OCV

18. Cylinder head gasket

Engine removal is not required for this procedure.

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Cylinder Head
Assembly > Cylinder Head > Repair procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.

• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Mark all wiring and hoses to avoid misconnection.

1. Disconnect the negative (-) battery terminal (A).

2. Remove the heater hoses (A).

3. Remove the intake & exhaust manifold. (Refer to Intake and exhaust system in this group)

4. Remove the water pump (A) and gasket (B).

5. Remove the water temperature control assembly (A) and gasket (B).

6. Remove the intake & exhaust CVVT assembly. (Refer to Timing system in this group)

7. Remove the intake & exhaust CVVT assembly.

Fix the cam shaft (A) with a wrench when removing the CVVT assembly.

8. Remove the cam shaft.
A. Remove the front cam shaft bearing cap (A).

B. Remove the exhaust cam shaft upper bearing (A).

C. Remove camshaft bearing cap (A), in the sequence shown.

D. Remove the cam shaft (A).

E. Remove the exhaust cam shaft lower bearing (A).

9. Use a torx wrench, remove the intake OCV (A).

10. Remove the exhaust OCV.

11. Remove the cylinder head bolts, then remove the cylinder head.

A. Using triple square wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the

sequence shown.

Head warpage or cracking could result from removing bolts in an incorrect order.

B. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on

a bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

12. Remove the cylinder head gasket.

Disassembl

y

Identify MLA(Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be
reinstalled in its original position.

1. Remove MLAs(A).

2. Remove valves.

(1) Using SST(09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

(2) Remove the spring retainer.

(3) Remove the valve spring.

(4) Remove the valve.

(5) Using valve stem seal remover (09222-29000), remove the valve stem seal.

Inspection

Cylinder Head

1. Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.

Flatness of cylinder head gasket surface

Standard : Less than 0.05mm(0.002in.)

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

Valve And Valve Spring

1. Inspect valve stems and valve guides.

(1) Using a caliper gauge, measure the inside diameter of the valve guide.

Valve guid I.D.

Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)

(2) Using a micrometer, measure the diameter of the valve stem.

Valve stem O.D.

Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

If the clearance is greater than maximum, replace the valve and valve guide.

Valve stem-to-guide clearance
[Standard]

Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)

[Limit]

Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)

2. Inspect valves.

(1) Check the valve is ground to the correct valve face angle.

(2) Check that the surface of the valve for wear.

If the valve face is worn, replace the valve.

(3) Check the valve head margin thickness.

If the margin thickness is less than minimum, replace the valve.

Margin

[Standard]
Intake : 1.02mm(0.0401in.)
Exhaust : 1.09mm(0.0429in.)

(4) Check the valve length.

Valve length
[Standard]

Intake : 113.18mm (4.456in.)
Exhaust : 105.84mm (4.167in.)

[Limit]

Intake : 112.93mm (4.446in.)
Exhaust : 105.59mm (4.157in.)

(5) Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, replace the valve.

3. Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width
should be within specifications and centered on the valve face.

4. Inspect valve springs.

(1) Using a steel square, measure the out-of-square of the valve spring.

(2) Using a vernier calipers, measure the free length of the valve spring.

If the free length is not as specified, replace the valve spring.

Valve spring

[Standard]
Free height : 47.44mm (1.8677in.)
Out-of-square : 1.5°

MLA

1. Inspect MLA.

Using a micrometer, measure the MLA outside diameter.

MLA O.D.

Intake/Exhaust :

31.964~31.980mm(1.2584 ~ 1.2590in.)

2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.

Tappet bore I.D.

Intake/Exhaust :

32.000~32.025mm(1.2598 ~ 1.2608in.)

3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.

MLA to tappet bore clearance

[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)

Camshaft

1. Inspect cam lobes.

Using a micrometer, measure the cam lobe height.

If the cam lobe height is less than standard, replace the camshaft.

Cam height

[Standard value]
Intake : 43.70 ~ 43.90mm (1.7204 ~ 1.7283in.)
Exhaust : 44.90 ~ 45.10mm (1.7677 ~ 1.7756in.)

2. Inspect camshaft journal clearance.

(1) Clean the bearing caps and camshaft journals.

(2) Place the camshafts on the cylinder head.

(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps.

Do not turn the camshaft.

(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

Bearing oil clearance
[Standard value]

Intake
No.1 journal : 0.022 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4,5, journal : 0.045 ~ 0.082mm (0.0018 ~ 0.0032in.)
Exhaust
No.1 journal : 0 ~ 0.032mm (0 ~ 0.0012in.)
No.2,3,4,5, journal : 0.045 ~ 0.082mm (0.0017 ~ 0.0032in.)

[Limit] :

Intake
No.1 journal : 0.09mm (0.0035in.)
No.2,3,4,5 journal : 0.12mm (0.0047in.)
Exhaust : 0.12mm (0.0047in.)

(7) Completely remove the plastigage.

(8) Remove the camshafts.

3. Inspect camshaft end play.

(1) Install the camshafts.

(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

Camshaft end play

[Standard value] : 0.04 ~ 0.16mm(0.0015 ~ 0.0062in.)
[Limit] : 0.20mm (0.0078in.)

(3) Remove the camshafts.

Exhaust Cam Shaft Bearing

1. Check the cylinder head bore mark.

Discrimination Of Cylinder Head

Location Of Cylinder Head Bore Mark

Class Mark Exhaust No.1 Inside Diameter Of Cylinder Head Bore

a A

40.000 ~ 40.008 mm
(1.5748 ~ 1.5751 in.)

b B

40.008 ~ 4.016 mm

(1.5751 ~ 1.5754 in.)

c C

40.016 ~ 40.024 mm
(1.5754 ~ 1.5757 in.)

2. Select class of camshaft bearing same as class of cylinder head as shown on the table below.

Discrimination Of Exhaust Camshaft Bearing

Place Of Exhaust Cam Shaft Bearing Identification Mark

Cylinder

Head Bore

Class

Bearing Class For Installing (Color) Thickness Of Bearing

a (A) C (Green)

1.996~2.000mm

(0.0785~0.0787in.)

b (B) B (None color)

2.000~2.004mm

(0.0787~0.0788in.)

c (C) A (Black)

2.004~2.008mm

(0.0788~0.0790in.)

Oil clearance : 0 ~ 0.032mm (0 ~ 0.0012in.)

CVVT Assembly

1. Inspect CVVT assembly.

(1) Check that the CVVT assembly will not turn.

(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.

Verify the hold to tape and the hole to put air in.

(3) Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port of the

camshaft.
(Perform this in order to release the lock pin.)

When the oil splashes, wipe it off with a shop rag and the likes.

(4) With air applied, as in step(3), turn the CVVT assembly to the advance angle side (the arrow marked direction

in the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by
hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the
port, there may be the case that the lock pin could be hardly released.

(5) Turn the CVVT assembly back and forth and check the movable range and that there is no disturbance.

Standard:

Should move smoothly in a range from about

22.5° (Intake) / 20.0° (Exhaust)

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (counter clockwise).

Reassembl

y

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

1. Install valves.

(1) Using SST(09222-4A000), push in a new oil seal.

Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2) Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.

(3) Using the SST(09222-3K000, 09222-3K100), 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.

(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure

proper seating of the valve and retainer lock.

2. Install MLAs.

Check that the MLA rotates smoothly by hand.

MLA can be reinstalled in its original position.

Installation

• Thoroughly clean all parts to be assembled.

• Always use a new head and manifold gasket.

• The cylinder head gasket is a metal gasket. Take care not to bend it.

• Rotate the crankshaft, set the No.1 piston at TDC.

1. Install OCV filter.

Keep the OCV filter clean.

2. Install the cylinder head gasket(A) on the cylinder block.

• Be careful of the installation direction.

• Apply liquid gasket (Loctite 5900H) on the edge of cylinder head gasket upside and downside. (At the
position 'B')

• After applying sealant, assemble the cylinder head in five minutes.

3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.

4. Install cylinder head bolts.
A. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.

B. Using hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in

the sequence shown.

Tightening torque :

32.4~36.3Nm (3.3~3.7kgf.m, 23.9~26.8lb-ft) + (90~95°) + (90~95°)

Always use new cylinder head bolt.

5. Install the OCV(A).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

• Do not reuse the OCV when dropped.

• Keep the OCV filter clean.

• Do not hold the OCV sleeve during servicing.

• When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.

6. Install the camshafts.

Apply a light coat of engine oil on camshaft journals.

A. Install the exhaust camshaft lower bearing (A).

B. Install the camshafts (A).

C. Install the exhaust camshaft upper bearing (A).

D. Install camshaft bearing caps in their proper locations.

Tightening order.
Group A ĺ Group B ĺ Group C.

Tightening torque

Step 1
M6 : 5.9N.m( 0.6kgf.m, 4.3lb-ft)
M8 : 14.7N.m( 1.5kgf.m, 10.8lb-ft)
Step 2
M6 : 10.8 ~ 12.7N.m(1.1 ~ 1.3kgf.m, 7.9 ~ 9.4lb-ft)
M8 : 27.5 ~ 31.4N.m(2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

7. Install the water temperature control assembly (A) with a new gasket (B).

Tightening torque :

Bolts : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.4lb-ft)
Nut : 18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

• Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for
assembling of water inlet pipe to be tightened.

• Always use a new O-ring.

8. Install the timing chain.

9. Check and adjust valve clearance.

10. Install the cylinder head cover.
A. The hardening sealant located on the upper area between timing chain cover and cylinder head should be

removed before assembling cylinder head cover.

B. After applying sealant, it should be assembled within 5 minutes.

Bead width : 2.5mm(0.1in.)
Sealant : LOCTITE 5900H

C. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was

assembled.

D. Install the cylinder head cover bolts as following method.

Tightening torque :

Step 1 : 3.9 ~ 5.9N.m(0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
Step 2 : 7.8 ~ 9.8N.m(0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Do not reuse cylinder head cover gasket.

11. Install the intake & exhaust manifold. (Refer to Intake and exhaust system in this group)

12. Install the heater hoses (A).

13. Connect the negative (-) battery terminal (A).

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Cylinder
Block > Cylinder Block > Components and Components Location

Components

1. Piston ring

2. Piston

3. Connecting rod

4. Connecting rod upper bearing

5. Piston pin

6. Connecting rod lower bearing

7. Connecting rod bearing cap

8. Ladder frame

9. Snap ring

1. Crankshaft upper bearing

2. Thrust bearing

3. Crankshaft

4. Crankshaft lower bearing

5. Main bearing cap

GENESIS COUPE(BK) >2010 > G 2.0 DOHC > Engine Mechanical System > Cylinder
Block > Cylinder Block > Repair procedures

Disassembl

y

1. M/T : remove the flywheel.

2. A/T : remove the drive plate.

3. Install the engine to the engine stand for disassembly.

4. Remove the timing chain. (Refer to Timing system in this group)

5. Remove the cylinder head. (Refer to Cylinder block in this group)

6. Remove the alternator(A) from engine.

7. Remove the tensioner assembly integrated bracket(A).

8. Remove the knock sensor(A).

9. Remove the water pump.

10. Remove the oil pump.

11. Remove the ladder frame(A).

12. Check the connecting rod end play.

13. Remove the connecting rod caps and check oil clearance.

14. Remove the piston and the connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.

• Arrange the piston and connecting rod assemblies in the correct order.

15. Remove the crankshaft bearing cap and check oil clearance.

16. Check the crankshaft end play.

17. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.

18. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a
set.

19. Remove the piston rings.
(1) Using a piston ring expender, remove the 2 compression rings.

(2) Remove 2 side rails and the spacer by hand.

Arrange the piston rings in the correct order only.

20. Disconnect the connecting rod from piston.

Inspection

Connecting Rod And Crankshaft

1. Check the connecting rod end play.

Using a feeler gauge, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)
Maximum end play : 0.35mm(0.0138in.)

A. If out-of-tolerance, install a new connecting rod.

B. If still out-of-tolerance, replace the crankshaft.

2. Check the connecting road bearing oil clearance.

(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

(2) Remove 2 connecting rod cap bolts.

(3) Remove the connecting rod cap and bearing half.

(4) Clean the crank pin and bearing.

(5) Place plastigage across the crank pin.

(6) Reinstall the bearing half and cap, and torque the bolts.

Tightening torque

17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

Do not turn the crankshaft.

(7) Remove 2 bolts, connecting rod cap and bearing half.

(8) Measure the plastigage at its widest point.

Standard oil clearance

0.025 ~ 0.043mm(0.0009 ~ 0.0016in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,

complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed

above or below that one), and check clearance again.

Discrimination Of Connecting Rod

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

Connecting Rod Mark Location

Class Mark Inside Diameter

A A

51.000 ~ 51.006mm
(2.0079 ~ 2.0081in.)

B B

51.006 ~ 51.012mm
(2.0081 ~ 2.0083in.)

C C

51.012 ~ 51.018mm
(2.0083 ~ 2.0085in.)

Discrimination Of Crankshaft

Discrimination Of Connecting Rod Bearing

Crankshaft Pin Mark Location Discrimination Of Crankshaft

Conform to read stamping order as shown arrow direction from #1.

Class Mark Outside Diameter Of Pin

I 1

47.966 ~ 47.972mm
(1.8884 ~ 1.8886in.)

II 2

47.960 ~ 47.966mm
(1.8881 ~ 1.8884in.)

III 3

47.954 ~ 47.960mm
(1.8879 ~ 1.8881in.)

Place Of Identification Mark (Connecting Rod Bearing) Discrimination Of
Connecting Rod Bearin

g

Class Mark Thickness Of Bearing

AA Blue

1.517 ~ 1.520mm

(0.0597 ~ 0.0598in.)

A Black

1.514 ~ 1.517mm

(0.0596 ~ 0.0597in.)

B None

1.511 ~ 1.514mm

(0.0595 ~ 0.0596in.)

1.508 ~ 1.511mm

C Green (0.0594 ~ 0.0595in.)

D Yellow

1.505 ~ 1.508mm

(0.0593 ~ 0.0594in.)

(11) Selection

Crankshaft Indentification Mark

Connecting Rod

Identification Mark

Assembing Classification Of

Bearing

I (1)

a (A) D (Yellow)

b (B) C (Green)

c (C) B (None)

II (2)

a (A) C (Green)

b (B) B (None)

c (C) A (Black)

III (3)

a (A) B (None)

b (B) A (Black)

c (C) AA (Blue)

3. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.

(2) Clean each main journal and bearing half with a clean shop tower.

(3) Place one strip of plastigage across each main journal.

(4) Reinstall the bearings and caps, then torque the bolts.

Tightening torque

14.7Nm (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125°

Do not turn the crankshaft.

(5) Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance

0.020 ~ 0.038mm (0.0008 ~ 0.0015in.)

(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,

complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed

above or below that one), and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

Connecting Rods

1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.

When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.

2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough

surface of the inside diameter of the small end is apparent, the rod must be replaced as well.

3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair

limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.

Crankshaft bore mark location

Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct
bearings.

Discrimination Of Cylinder Block

Allowable bend of connecting rod :

0.05mm / 100mm (0.0020 in./3.94 in.) or less

Allowable twist of connecting rod :

0.1mm / 100mm (0.0039 in./3.94 in.) or less

Calss Mark Inside Diameter

a A

56.000 ~ 56.006mm

Discrimination Of Crankshaft

Discrimination Of Crankshaft Bearing

(2.2047 ~ 2.2049in.)

b B

56.006 ~ 56.012mm
(2.2049 ~ 2.2052in.)

c C

56.012 ~ 56.018mm
(2.2052 ~ 2.2054in.)

Crankshaft Journal Mark Location Discrimination Of Crankshaft

Conform to read stamping order as shown arrow direction from #1.

Class Mark Outside Diameter Of Journal

I 1

51.954 ~ 51.960mm
(2.0454 ~ 2.0456in.)

II 2

51.948 ~ 51.954mm
(2.0452 ~ 2.0454.)

III 3

51.942 ~ 51.948mm

(2.0449 ~ 2.0452in.)

Place Of Identification Mark (Crankshaft Bearing) Discrimination Of Crankshaft
Bearin

g

Class Mark Thickness Of Bearing

AA Blue

2.026 ~ 2.029mm

(0.0797 ~ 0.0798in.)

Selection

A Black

2.023 ~ 2.026mm

(0.0796 ~ 0.0797in.)

B None

2.020 ~ 2.023mm

(0.0795 ~ 0.0796in.)

C Green

2.017 ~ 2.020mm

(0.0794 ~ 0.795in.)

D Yellow

2.014 ~ 2.017mm

(0.0793 ~ 0.0794in.)

Crankshaft Identification Mark

Crankshaft Bore Identification

Mark

Assembling Classification Of

Bearing

I (1)

a (A) D (Yellow)

b (B) C (Green)

c (C) B (None)

II (2)

a (A) C (Green)

b (B) B (None)

c (C) A (Black)

III (3)

a (A) B (None)

b (B) A (Black)

c (C) AA (Blue)

4. Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

If the end play is greater than maximum, replace the thrust bearings as a set.

Standard end play

0.07 ~ 0.25mm (0.0027 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)

Thrust bearing thickness

1.925 ~ 1.965mm(0.0758 ~ 0.07736in.)

5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter :

51.942 ~ 51.960mm (2.0449 ~ 2.0456in.)

Crank pin diameter :

47.954 ~ 47.972mm (1.8879 ~ 1.8886in.)

Cylinder Block

1. Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.

Flatness of cylinder block gasket surface

Standard : Less than 0.05mm(0.0020 in.)

4. Inspect cylinder bore diameter
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.

5. Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.

Standard diameter

86.00 ~ 86.03mm (3.3858 ~ 3.3870in.)

Measure position(from the bottom of the cylinder block)
: 110.7mm(4.3582in.) / 160mm (6.2992in.) / 210mm (8.2677in.)

6. Check the cylinder bore size code on the cylinder block.

Cylinder Bore Inner Diameter

Size Code Inner Diameter

A 86.00 ~ 86.01mm (3.3853 ~ 3.3862in.)

B 86.01 ~ 86.02mm (3.3862 ~ 3.3866in.)

C 86.02 ~ 86.03mm (3.3866 ~ 3.3870in.)

7. Check the piston size code on the piston top face.

Piston Outer Diameter

Stamp the grade mark of basic diameter with rubber stamp.

Size Code Outer Diameter

A 85.975 ~ 85.985mm (3.3848 ~ 3.3852in.)

B 85.985 ~ 85.995mm (3.3852 ~ 3.3856in.)

C 85.995 ~ 86.005mm (3.3856 ~ 3.3860in.)

8. Select the piston related to cylinder bore class.

Clearance : 0.015 ~ 0.035mm (0.00059 ~ 0.00137in.)

Piston And Rings

1. Clean piston

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 14 mm (0.55 in.) from the top land of the
piston.

Standard diameter

85.975 ~ 86.005mm (3.3848 ~ 3.3860in.)

3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance

0.015 ~ 0.035mm(0.00059 ~ 0.00137in.)

4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

If the clearance is greater than maximum, replace the piston.

Piston ring side clearance

Standard
No.1 : 0.05 ~ 0.08mm (0.0019 ~ 0.0031in.)
No.2 : 0.04 ~ 0.08mm (0.0015 ~ 0.0031in.)
Oil ring : 0.06 ~ 0.15mm (0.0023 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)

5. Inspect piston ring end gap.
To measure 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 exceeds
the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the
wear limits, If the bore is over the service limit, the cylinder block must be rebored.

Piston ring end gap

Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.37 ~ 0.52m (0.0145 ~ 0.0204in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)

Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

Piston Pins

1. Measure the diameter of the piston pin.

Piston pin diameter

21.997 ~ 22.000mm (0.8660 ~ 0.8661in.)

2. Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance

0.003 ~ 0.010mm (0.00011 ~ 0.00039in.)

Oil Pressure Switch

1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

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.

3. If there is no continuity when a 50kpa (7psi) is applied throgh the oil hole, the switch is operaing properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

Reassembl

y

• Thoroughly clean all parts to assembled.

• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

• Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble the piston and connecting rod.

(1) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

(2) Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.

• Apply heat to the piston (70°C) and then install the piston pin.

• Take care that piston pin is not to be damaged during pressing process.

• When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner
diameter as below.

Piston pin outer DIA. :

21.997mm ~ 22.000mm (0.8660 ~ 0.8661 in)
Connecting rod S/END inner DIA. :

22.005mm ~ 22.011mm (0.8663 ~ 0.8665 in)

• Take care that piston is not to be damaged during installing process. When replace the piston pin, check
the gap as below.

Connecting rod bushing gap :

0.005mm ~ 0.014mm (0.00019 ~ 0.00055 in)
Piston pin BOSS gap :

0.003mm ~ 0.010mm (0.00012 ~ 0.00039 in) - Heat to 70°C

2. Install the piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.

(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.

(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.
(1) Align the bearing claw with the groove of the connecting rod or connecting rod cap.

(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).

4. Install the main bearings.

Upper bearings have an oil groove of oil holes; Lower bearings do not.

(1) Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).

(2) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

5. Install the thrust bearings.

Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

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

7. Place the main bearing caps on cylinder block.

8. Install the main bearing cap bolts.

Tightening torque

14.7Nm (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125°

• The main bearing cap bolts are tightened in 2 progressive steps.

• If any of the bearing cap bolts in broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.

(2) Install and uniformly tighten the 10 bearing cap bolts(A), in several passes, in the sequence shown.

(3) Retighten the bearing cap bolts by 120° in the numerical order shown. (Using the SST (09221-4A000))

(4) Check that the crankshaft turns smoothly.

9. Check crankshaft end play.

10. Install the piston and connecting rod assemblies.

Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.

(1) Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the

connecting rod bolts.

(2) Install the ring compressor, check that the bearing is securely in place, then position the piston in the

cylinder, and tap it in using the wooden handle of a hammer.

(3) Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before

pushing the piston into place.

Maintain downward force on the ring compressor to prevent the rings from expanding before entering the
cylinder bore.

(4) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

Tightening torque

17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

Always use new connecting rod bolt.

11. Install the ladder frame (A).

Tightening torque :

23.5 ~ 27.5N.m(2.4 ~ 2.8kgf.m, 17.4 ~ 20.2lb-ft)

• Before assembling ladder frame, the liquid sealant Loctite 5900H or THREEBOND 1217H should be
applied ladder frame.

• The part must be assembled within 5 minutes after sealant was applied.

• Apply sealant to the inner threads of the bolt holes.

12. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.

(2) Using SST (09231-H1100, 09214-3K100) and a hammer, tap in the oil seal until its surface is flush with the

rear oil seal retainer edge.

13. Install the oil pump.

14. Install the water pump.

15. Install the knock sensor(A).

Tightening torque

16.7 ~ 25.5N.m (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8lb-ft)

16. Install the tensioner assembly integrated bracket(A).

Tightening torque

39.2 ~ 44.1N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)