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HOMESERVICE MANUALSHYUNDAI2003SANTA FE V6-2.7LREPAIR AND DIAGNOSISSPECIFICATIONSMECHANICAL SPECIFICATIONSENGINECYLINDER BLOCK ASSEMBLYSYSTEM SPECIFICATIONS
2003 Hyundai Santa Fe V6-2.7L
System Specifications
2003 Hyundai Santa Fe V6-2.7LSECTION System Specifications
General
Piston
Diameter (Standard) 86.68 - 86.71 mm (3.413 - 3.414 inch)
Clearance (Piston-to-cylinder) 0.01 - 0.03 mm (0.0004 - 0.0012 inch)
Ring groove width
No.1 1.230 - 1.250 mm (0.0484 - 0.0492 inch)
No.2 1.220 - 1.240 mm (0.0480 - 0.0488 inch)
Oil 2.515 - 2.535 mm (0.0990 - 0.0998 inch)
Piston for service 0.25 mm (0.010 inch), 0.50 mm (0.020 inch)
Piston ring
Number of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No.1 Inner bevel type.
No.2 Under cut type
Oil ring type 3-piece type
Ring end gap
No.1
Specification 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit 0.8 mm (0.031 inch)
No.2
Specification 0.37 - 0.52 mm (0.0146 - 0.0205 inch)
Limit 0.8 mm (0.031 inch)
Oil ring side rail
Specification 0.2 - 0.7 mm (0.0079 - 0.0276 inch)
Limit 1.0 mm (0.039 inch)
Ring side clearance
No.1
Specification 0.04 - 0.08 mm (0.0016 - 0.0031 inch)
Limit 0.1 mm (0.004 inch)
No.2
Specification 0.03 - 0.07 mm (0.0012 - 0.0028 inch)
Limit 0.1 mm (0.004 inch)
Rings for service 0.25 mm (0.010 inch), 0.50 mm (0.020 inch)
Connecting rod
Piston pin installation force 2,450 - 12,255 N (250 - 1,250 kg, 551 - 2,755 lb)
Side clearance (big end)
Specification 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit 0.4 mm (0.016 inch)
Bend 0.05 mm or less/100 mm (0.0020 in. or less/3.937 inch)
Bearing oil clearance
Specification 0.018 - 0.036 mm (O.0007 - 0.0014 inch)
Limit 0.1 mm (0.004 inch)
Crankshaft
Journal O.D. 61.982 - 62.000 mm (2.4402 - 2.4409 inch)
Pin O.D. 47.982 - 48.000 mm (1.8891 - 1.8898 inch)
Out-of-round of journal and pin Max. 0.003 mm (0.00012 inch)
Taper of journal and pin Max. 0.005 mm (0.00020 inch)
End play
Specification 0.070 - 0.250 mm (0.0028 - 0.0098 inch)
Limit 0.4 mm (0.016 inch)
Main bearing oil clearance
Specification 0.004 - 0.022 mm (0.0002 - 0.0009 inch)
Limit 0.1 mm (0.004 inch)
Cylinder block
Cylinder bore 86.7 mm (3.4134 inch)
Flatness of gasket surface
Specification Max. 0.03 mm (0.0012 inch)
Limit 0.05 mm (0.002 inch)
Out-of-round of cylinder bore Max. 0.02 mm (0.0008 inch)
TIGHTENING TORQUE
Main bearing cap bolt
M10 27 - 33 Nm (19.5 - 24 ft. lbs.) + 90 - 94°
M8 13 - 19 Nm (10 - 14 ft. lbs.) + 90 - 94°
Crank position sensor wheel screw 5 - 6 Nm (3.6 - 4.3 ft. lbs.)
Crankshaft pulley bolt 180 - 190 Nm (130 - 138 ft. lbs.)
Piston
Diameter (Standard) 86.68 - 86.71 mm (3.413 - 3.414 inch)
Clearance (Piston-to-cylinder) 0.01 - 0.03 mm (0.0004 - 0.0012 inch)
Ring groove width
No.1 1.230 - 1.250 mm (0.0484 - 0.0492 inch)
No.2 1.220 - 1.240 mm (0.0480 - 0.0488 inch)
Oil 2.515 - 2.535 mm (0.0990 - 0.0998 inch)
Piston for service 0.25 mm (0.010 inch), 0.50 mm (0.020 inch)
PISTON RING SERVICE SIZE AND MARK:
Piston ring
Number of rings per piston 3
Compression ring 2
Oil ring 1
Compression ring type
No.1 Inner bevel type.
No.2 Under cut type
Oil ring type 3-piece type
Ring end gap
No.1
Specification 0.20 - 0.35 mm (0.0079 - 0.0138 inch)
Limit 0.8 mm (0.031 inch)
No.2
Specification 0.37 - 0.52 mm (0.0146 - 0.0205 inch)
Limit 0.8 mm (0.031 inch)
Oil ring side rail
Specification 0.2 - 0.7 mm (0.0079 - 0.0276 inch)
Limit 1.0 mm (0.039 inch)
Ring side clearance
No.1
Specification 0.04 - 0.08 mm (0.0016 - 0.0031 inch)
Limit 0.1 mm (0.004 inch)
No.2
Specification 0.03 - 0.07 mm (0.0012 - 0.0028 inch)
Limit 0.1 mm (0.004 inch)
Rings for service 0.25 mm (0.010 inch), 0.50 mm (0.020 inch)
CONNECTING ROD 2.7L:
Connecting rod
Piston pin installation force 2,450 - 12,255 N (250 - 1,250 kg, 551 - 2,755 lb)
Side clearance (big end)
Specification 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Limit 0.4 mm (0.016 inch)
Bend 0.05 mm or less/100 mm (0.0020 in. or less/3.937 inch)
Bearing oil clearance
Specification 0.018 - 0.036 mm (O.0007 - 0.0014 inch)
Limit 0.1 mm (0.004 inch)
Crankshaft
Journal O.D. 61.982 - 62.000 mm (2.4402 - 2.4409 inch)
Pin O.D. 47.982 - 48.000 mm (1.8891 - 1.8898 inch)
Out-of-round of journal and pin Max. 0.003 mm (0.00012 inch)
Taper of journal and pin Max. 0.005 mm (0.00020 inch)
End play
Specification 0.070 - 0.250 mm (0.0028 - 0.0098 inch)
Limit 0.4 mm (0.016 inch)
Main bearing oil clearance
Specification 0.004 - 0.022 mm (0.0002 - 0.0009 inch)
Limit 0.1 mm (0.004 inch)
Cylinder block
Cylinder bore 86.7 mm (3.4134 inch)
Flatness of gasket surface
Specification Max. 0.03 mm (0.0012 inch)
Limit 0.05 mm (0.002 inch)
Out-of-round of cylinder bore Max. 0.02 mm (0.0008 inch)
TIGHTENING TORQUE
Main Bearing Cap Bolt Tightening Sequence:
Main bearing cap bolt
M10 27 - 33 Nm (19.5 - 24 ft. lbs.) + 90 - 94°
M8 13 - 19 Nm (10 - 14 ft. lbs.) + 90 - 94°
Crank position sensor wheel screw 5 - 6 Nm (3.6 - 4.3 ft. lbs.)
Crankshaft pulley bolt 180 - 190 Nm (130 - 138 ft. lbs.)
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.