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Discussion Starter · #1 · (Edited)
Okay guys here are some diagrams/part locations for our cars. Obviously I can't upload all, but anything you guys need specifically post it in this thread and I will do my best to get it for you!


Description
Specifications
Limit
Except Europe
General
Type
In-line, DOHC
 
Number of cylinders
4
 
Bore
77mm (3.0315in)
 
Stroke
85.44mm (3.3638in)
 
Total displacement
1,591 cc (97.09 cu.in)
 
Compression ratio
9.5 : 1
 
Firing order
1-3-4-2
 
Valve timing
Intake valve
Opens
ATDC 8°/BTDC 42°
 
Closes
ABDC 69°/ABDC 19°
 
Exhaust valve
Opens
BBDC 40°/BBDC 0°
 
Closes
ATDC 3°/ATDC 43°
 
Cylinder head
Flatness of gasket surface
Less than 0.05mm (0.0020in) for total area
Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in) X 100mm (3.9370in)
 
Camshaft
Cam height
Intake
44.15mm (1.7382in)
 
Exhaust
42.90mm (1.6889in)
 
Journal outer diameter (Intake, Exhaust)
22.964 ~ 22.980mm (0.9041 ~ 0.9047in)
 
Camshaft cap oil clearance
0.027 ~ 0.058mm (0.0011 ~ 0.0023in)
0.1mm (0.0039in)
End play
0.10 ~ 0.20mm (0.0039 ~ 0.0079in)
 
Valve
Valve length
Intake
93.15mm (3.6673in)
 
Exhaust
92.60mm (3.6457in)
 
Stem outer diameter
Intake
5.465 ~ 5.480mm (0.2152 ~ 0.2157in)
 
Exhaust
5.458 ~ 5.470mm (0.2149 ~ 0.2154in)
 
Face angle
45.25° ~ 45.75°
 
Thickness of valve head (margin)
Intake
1.10mm (0.0433in)
0.8mm (0.0315in)
Exhaust
1.26mm (0.0496in)
1.0mm (0.0394in)
Valve stem to valve guide clearance
Intake
0.020 ~ 0.047mm (0.0008 ~ 0.0019in)
0.10mm (0.0039in)
Exhaust
0.030 ~ 0.054mm (0.0012 ~ 0.0021in)
0.15mm (0.0059in)
Valve guide
Length
Intake
40.3 ~ 40.7mm (1.5866 ~ 1.6024in)
 
Exhaust
40.3 ~ 40.7mm (1.5866 ~ 1.6024in)
 
Valve spring
Free length
45.1mm (1.7756in)
 
Out of squareness
Less than 1.5°
 
Cylinder block
Cylinder bore
77.00 ~ 77.03mm (3.0315 ~ 3.0327in)
 
Flatness of gasket surface
Less than 0.05mm (0.0020in) for total area
Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in) X 100mm (3.9370in)
 
Piston
Piston outer diameter
76.97 ~ 77.00mm (3.0303 ~ 3.0315in)
 
Piston to cylinder clearance
0.020 ~ 0.040mm (0.0008 ~ 0.0016in)
 
Ring groove width
No. 1 ring groove
1.23 ~ 1.25mm (0.0484 ~ 0.0492in)
1.26mm (0.0496in)
No. 2 ring groove
1.53 ~ 1.55mm (0.0602 ~ 0.0610in)
1.26mm (0.0496in)
Oil ring groove
2.01 ~ 2.03mm (0.0791 ~ 0.0799in)
2.05mm (0.0807in)
Piston ring
Side clearance
No.1 ring
0.04 ~ 0.08mm (0.0016 ~ 0.0031in)
0.1 mm (0.0039in)
No.2 ring
0.04 ~ 0.08mm (0.0016 ~ 0.0031in)
0.1 mm (0.0039in)
Oil ring
0.02 ~ 0.06mm (0.0008 ~ 0.0024in)
0.2 mm (0.0079in)
End gap
No. 1 ring
0.14 ~ 0.28mm (0.0055 ~ 0.0110in)
0.30mm (0.0118in)
No. 2 ring
0.30 ~ 0.45mm (0.0118 ~ 0.0177in)
0.50mm (0.0197in)
Oil ring
0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
0.80mm (0.0315in)
Piston pin
Piston pin outer diameter
19.997 ~ 20.000mm (0.7872 ~ 0.7874in)
 
Piston pin hole inner diameter
20.004 ~ 20.010mm (0.7875 ~ 0.7877in)
 
Piston pin hole clearance
0.004 ~ 0.013mm (0.0001 ~ 0.0005in)
 
Connecting rod small end hole inner diameter
20.005 ~ 20.016mm (0.7875 ~ 0.7880in)
 
Connecting rod
Connecting rod big end inner diameter
45.000 ~ 45.018mm (1.7717 ~ 1.7724in)
 
Connecting rod bearing oil clearance
0.018 ~ 0.036mm (0.0007 ~ 0.0014in)
0.060mm (0.0024in)
Side clearance
0.10 ~ 0.25mm (0.0039 ~ 0.0098in)
0.35m (0.0138in)
Crankshaft
Main bearing oil clearance
No. 1, 2, 3, 4, 5
0.0006 ~ 0.024mm (0.0002 ~ 0.0009in)
0.05mm (0.0020in)
End play
0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
0.3mm (0.0118in)
Engine oil
Oil quantity
Total
4.9 L (1.29 U.S.gal., 5.17 U.S.qt., 4.30 lmp.qt.)
When replacing a short engine or a block assembly
Oil pan
4.2 L (1.10 U.S.gal., 4.43 U.S.qt., 1.10 lmp.qt.)
 
Drain and refill
4.5 L (1.18 U.S.gal., 4.75 U.S.qt., 3.95 lmp.qt.)
Including oil filter
Oil grade
Recommendation
ACEA A5 or above
(ZIC LD 5W-30, KIXX G1 LL, QUARTZ HKS G-310, QUARTZ INEO MC3 5W-30, HELIX ULTRA AH-E 5W-30, HELIX ULTRA 5W-40, TITAN SUPERSYN LONG LIFE 5W-30/40)
SAE viscosity grade
5W-30, 5W-40
 
Oil pressure (at 1000rpm)
100kPa (1.0kg/cm², 14.5psi) or above
Oil temperature in oil pan : 110±2°C (230± 36°F)
Cooling system
Cooling method
Forced circulation with cooling fan
 
Coolant quantity
6.1 L (1.61 U.S.gal., 6.44 U.S.qt., 5.36 lmp.qt.)
5.9 L (1.55 U.S.gal., 6.23 U.S.qt., 5.18 lmp.qt.)
 
Thermostat
Type
Wax pellet type
 
Opening temperature
82 ± 1.5°C (179.6 ± 2.7°F)
 
Full opening temperature
95°C (203°F)
 
Radiator cap
Main valve opening pressure
93.16 ~ 122.58kpa
(0.95 ~ 1.25kgf/cm², 13.51 ~ 17.78psi)
 
Vacuum valve opening pressure
MAX. 6.86 kpa(0.07kgf/cm², 1.00 psi)
 
Water temperature sensor
Type
Thermister type
 
Resistance
20°C (68°F)
2.45±0.14 kΩ
 
80°C (176°F)
0.3222 kΩ
 

Tightening Torques
Item
Quantity
N.m
kgf.m
lb-ft
Engine mounting
Engine mounting bracket to body fixing bolt
3
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Engine mounting support bracket to engine mounting insulator fixing nut
1
63.7 ~ 83.4
6.5 ~ 8.5
47.0 ~ 61.5
Engine mounting support bracket to engine support bracket fixing bolt
1
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Engine mounting support bracket to engine support bracket fixing nut
2
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Transaxle mounting bracket to body fixing bolt
3
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Transaxle mounting insulator to transaxle mounting support bracket fixing bolt
2
88.3 ~ 107.9
9.0 ~ 11.0
65.1 ~ 79.6
Roll rod bracket to sub frame fixing bolt
2
49.0 ~ 63.7
5.0 ~ 6.5
36.2 ~ 47.0
Roll rod insulator to roll rod mounting support bracket fixing nut
1
107.9 ~ 127.5
11.0 ~ 13.0
79.6 ~ 94.0
Timing system
Timing chain and oil pump assembly cover bolt (M6×20)
10
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain and oil pump assembly cover bolt (M6×38)
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain and oil pump assembly cover bolt (M6×70)
1
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain and oil pump assembly cover bolt (M8×22)
3
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Idler pulley assemlby bolt
1
42.2 ~ 53.9
4.3 ~ 5.5
31.1 ~ 39.8
Timing chain tensioner arm bolt
1
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Timing chain guide bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Crankshaft pulley bolt
1
[47.0 ~ 50.9] + [38°~ 42°]
[4.8 ~ 5.2] + [38°~ 42°]
[34.7 ~ 37.6] + [38°~ 42°]
Engine support bracket bolt
4
29.4 ~ 41.1
3.0 ~ 4.2
21.6 ~ 30.3
Timing chain tensioner bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder head
Ignition coil bolt
4
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
High pressure fuel pipe nut
2
25.5 ~ 31.4
2.6 ~ 3.2
18.8 ~ 23.1
High pressure fuel pump bolt
2
12.7 ~ 14.7
1.3 ~ 1.5
9.4 ~ 10.8
Cylinder head cover bolt
19
[3.9~5.9] + [7.8~9.8]
[0.4~0.6] + [0.8~1.0]
[2.9~4.3] + [5.8~7.2]
Camshaft bearing cap bolt (M6)
18
[5.9] + [11.8~13.7]
[0.6] + [1.2~1.4]
[4.3] + [8.7~10.1]
Camshaft bearing cap bolt (M8)
4
18.6 ~ 22.6
1.9 ~ 2.3
13.7 ~ 16.6
Cylinder head bolt
10
[29.4] + [90°] + [90°]
[3.0] + [90°] + [90°]
[21.7] + [90°] + [90°]
CVVT assembly mounting bolt
2
63.7 ~ 73.5
6.5 ~ 7.5
47.0 ~ 54.2
OCV (Oil control valve) bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Exhaust OCV (Oil control valve) adaptor bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder block
Engine support bracket bolt
4
29.4 ~ 41.2
3.0 ~ 4.2
21.7 ~ 30.4
Ladder frame bolt
13
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Connecting rod cap bolt
8
[17.7~21.6] + [88~92°]
[1.8~2.2] + [88~92°]
[13.0~15.9] + [88~92°]
Crankshaft main bearing cap bolt
10
[19.6] + [90°]
[2.0] + [90°]
[14.5] + [90°]
Flywheel bolts (M/T)
6
71.6 ~ 75.5
7.3 ~ 7.7
52.8 ~ 55.7
Drive plate bolts (A/T)
6
71.6 ~ 75.5
7.3 ~ 7.7
52.8 ~ 55.7
Lubrication system
Oil filter
1
11.8 ~ 15.7
1.2 ~ 1.6
8.7 ~ 11.6
Oil pan bolt
11
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Oil pan drain plug
1
34.3 ~ 44.1
3.5 ~ 4.5
25.3 ~ 32.5
Oil screen bolt
2
19.6 ~ 26.5
2.0 ~ 2.7
14.5 ~ 19.5
Oil pressure switch
1
7.8 ~ 11.8
0.8 ~ 1.2
5.8 ~ 8.7
Oil level gauge assembly mounting bolt
1
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cooling system
Water pump pulley bolt
4
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Water pump bolt
5
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Water temperature control assembly mounting bolt
3
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Water inlet fitting nut
2
18.6 ~ 23.5
1.9~ 2.4
13.7 ~ 17.4
Heater pipe mounting bolt (M6)
1
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Heater pipe mounting nut
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Heater pipe mounting bolt (M8)
1
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Engine coolant temperature sensor (ECTS)
1
29.4 ~ 39.2
3.0 ~ 4.0
21.7 ~ 28.9
Intake and exhaust system
Air intake hose clamp bolt
2
2.9 ~ 4.9
0.3 ~ 0.5
2.2 ~ 3.6
Air cleaner asembly bolt
2
7.8 ~ 9.8
0.8 ~ 1.0
5.8 ~ 7.2
Electronic throttle control (ETC) module bolt
4
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Intake manifold nut
2
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.4
Vacuum pipe mounting bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo manifold module heat protector mounting bolt
3
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Cylinder head cover heat protector mounting bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo charger oil drain pipe bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo charger oil drain pipe nut
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo charger oil feed pipe bolt
2
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo charger oil feed pipe eyebolt
1
11.7 ~ 17.6
1.2 ~ 1.8
8.6 ~ 13.0
Turbo charger pipe & hose bolt
1
9.8 ~ 11.8
1.0 ~ 1.2
7.2 ~ 8.7
Turbo charger water pipe & hose eyebolt
2
26.4 ~ 32.3
2.7 ~ 3.3
19.5 ~ 23.8
Turbo manifold module mounting nut
9
35.3 ~ 41.1
3.6 ~ 4.2
26.0 ~ 30.3
Turbo charger coupler mounting nut
3
35.3 ~ 41.1
3.6 ~ 4.2
26.0 ~ 30.3
Intake pipe stay mounting bolt (M8)
6
18.6 ~ 23.5
1.9 ~ 2.4
13.7 ~ 17.3
Intake pipe stay mounting bolt(M10)
1
29.4 ~ 34.3
3.0 ~ 3.5
21.6 ~ 25.3
Intake pipe mounting bolt
1
29.4 ~ 34.3
3.0 ~ 3.5
21.6 ~ 25.3
Intake pipe mounting nut
2
35.3 ~ 41.1
3.6 ~ 4.2
26.0 ~ 30.3
Intercooler inlet pipe mounting bolt
2
19.6 ~ 26.4
2.0 ~ 2.7
14.4 ~ 19.5
Catalytic convertor mounting nut
2
49.0 ~ 53.9
5.0 ~ 5.5
36.1 ~ 39.7
Muffler monting nut
4
39.2 ~ 58.8
4.0 ~ 6.0
28.9 ~ 43.4


ALL TORQUE SPECS ARE IN NM YOU HAVE TO CONVERT TO LBS
 

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Discussion Starter · #2 ·
1.
Disconnect the battery negative terminal.
2.
Disconnect the boost pressure sensor connector(A) RCV solenoid valve connector(B) cooling fan controller connector(C).
3.
Disconnect the vacuum hose(D).
Engine Auto part Vehicle Car Automotive engine part


4.
Disconnect the intercooler outlet hose.
(Refer to Intake and Exhaust System - "Intercooler pipe & hose")
5.
Disconnect the intercooler inlet hose.
(Refer to Intake and Exhaust System - "Intercooler pipe & hose")
6.
Remove the radiator upper bracket(A).
7.
Disconnect the RCV hose(A) and then remove the intercooler(B).
Engine Auto part Vehicle Car Mid-size car


8.
Install in the reverse order of removal.
Auto part Engine Vehicle Automotive exterior Automotive engine part
 

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Discussion Starter · #3 ·
Anyone want anything specific to be posted?
 

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Discussion Starter · #4 ·
Auto part Automotive engine part Automotive super charger part Automotive starter motor Carburetor

1. Turbine housing
2. Turbine inlet
3. Turbine outlet
4. Compressor housing
5. Compressor inlet
6. Compressor outlet
7. Center housing
8. Actuator
9. Actuator rod
 

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Discussion Starter · #5 ·
Vehicle Auto part Engine Car Pipe
Vehicle Auto part Engine Car Pipe


General Description
RCV (Recirculation Valve) is mounted on top of the intercooler innet pipe. It functions as a controler of bypass passage for turbo charger compressor.
If the throttle body gets closed suddenly during engine running, boost pressure gets higher. RCV prevents this high pressure air from moving reversely and making an impact noise with impeller of compressor by sending this high pressure air into compressor .
DTC Description
If there is Open in RCV circuit, ECM sets DTC P0033.
DTC Detecting Condition
Item
Detecting Condition
Possible Cause
DTC Strategy

Circuit check, Open
1.
Poor Connection
2.
Open Circuit
3.
RCV
Enable Conditions

IG ON
Threshold Value

Circuit open
Diagnostic Time

Continuous
MIL ON Condition

2 driving cycles

Specification
Item
Specification
Coil Resistance(Ω)
29.7 ± 1.4 Ω (20°C(68°F))

Diagnostic Circuit Diagram

Signal Waveform & Data
Text Blue Line Font Parallel


Fig.1) Waveform of RCV and Boost Presure Sensor before & after acceleration
 

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Discussion Starter · #6 ·
Text Font Map Auto part Line art

1. Turbo manifold gasket
2. Turbo manifold module
3. Turbo charger coupler
4. Turbo charger coupler & gasket
5. Oil feed pipe & hose assembly
6. Oil drain pipe assembly
7. Turbo manifold module heat protector
8. Turbo charger water pipe & hose assembly
9. Turbo charger stay
10. Intake pipe
11. Intake pipe gasket
 

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Discussion Starter · #7 ·
Also, if you guys need something not Veloster related PM me and I can get it. Anything from Ferrari to Geo (exception of Bugatti Veyron).
 

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Very nice MV! Thanks for the thread!
 
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Discussion Starter · #10 ·
No problem guys, like I said if you want anything specific or think of something that should be on here for other members let me know.
 
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Reactions: Gerid

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I'd take a exhaust schematic if you could get a hold of one so I can have something to work with before I hit the exhaust shop Saturday!
 

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The amp wire codes can be found and are straight forward. They are all bundled in a wire loom which sucks ass.... but if you split it and tug you can spice things in at the stock amp location like I did. Do a good job. You dont wanna have to go back in there to redo things.
 

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The amp wire codes can be found and are straight forward. They are all bundled in a wire loom which sucks ass.... but if you split it and tug you can spice things in at the stock amp location like I did. Do a good job. You dont wanna have to go back in there to redo things.
I used the sub wires. But at the amp like you is where I want to splice into to get a better range. You have a pic and op can get me the diagram ;)
 

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Discussion Starter · #15 ·
I'd take a exhaust schematic if you could get a hold of one so I can have something to work with before I hit the exhaust shop Saturday!
Vehicle Auto part Car

Motor vehicle Auto part Vehicle Automotive exhaust Exhaust system
 
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