Hyundai Sonata: Cylinder Block Repair procedures - Cylinder Block - Engine Mechanical SystemHyundai Sonata: Cylinder Block Repair procedures

Removal
Engine removal is required for this procedure.
(Refer to Engine and transaxle assembly removal in this group)
1.
MT : Remove the flywheel.
(Refet to Cylinder Block - "Flywheel")
2.
AT : Remove the drive plate.
(Refet to Cylinder Block - "Drive Plate")
3.
Remove the engine to engine stand for disassembly.
4.
Remove the timing chain.
(Refet to Timing System - "Timing Chain")
5.
Remove the cylinder head.
(Refet to Cylindet Head Assembly - "Cylinder Head")
6.
Remove the water jacket.
(Refer to Cylinder Block - "Water Jacket")
7.
Remove the oil level gauge tube.
8.
Remove the knock sensor (A) and the oil filter (B).

9.
Remove the oil pressure switch.
(Refet to Lubrication System - "Oil Pressure Switch")
10.
Remove the oil pan.
(Refer to Lubrication System - "Oil Pan")
11.
Remove the oil screen (A).

12.
Remove the rear oil seal.
(Refet to Cylinder Block - "Rear Oil Seal")
13.
Remove the ladder frame (A).

14.
Check the connecting rod end play.
15.
Remove the connecting rod caps and check oil clearance.
16.
Remove the piston and 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.
17.
Remove the crankshaft bearing cap and check oil clearance.
18.
Check the crankshaft end play.
19.
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.

20.
Remove the piston cooling jet (A).

21.
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.
22.
Remove the piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings.
(2)
Remove the 2 side rails and coil spring.
   
Arrange the piston rings in the correct order only.
23.
Remove the connecting rod from the piston.
Using a press, remove the piston pin from piston.
(Press-in load : 500~1,500kg(1,102~3,306lb))
Inspection
Connecting Rod And Crankshaft
1.
Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting rod back and forth.

End play
Standard : 0.10 ~ 0.25mm (0.0039 ~ 0.0098in)
Maximum : 0.35mm (0.0138in)

   
If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance, replace the crankshaft.
2.
Check the connecting rod bearing oil clearance.
(1)
Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2)
Remove the 2 connecting rod cap bolts.
(3)
Remove the connecting rod cap and lower bearing.
(4)
Clean the crankshaft pin journal and bearing.
(5)
Place a plastigage across the crankshaft pin journal.
(6)
Reinstall the lower bearing and cap, and tighten the bolts. Do not reuse the bolts.

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

   
Do not turn the crankshaft.
(7)
Remove the 2 bolts, connecting rod cap and lower bearing .
(8)
Measure the plastigage at its widest point.

Standard oil clearance
0.032 ~ 0.052mm (0.0013 ~ 0.0020in)

(9)
If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.
Recheck the oil clearance.
   
Do not file, shim, of 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.
   
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and restart 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

Discrimination Of Connecting Rod
Mark
Connecting rod big-end
inner diameter
A, 0
45.000 ~ 45.006mm (1.7717 ~ 1.7719in)
B, 00
45.006 ~ 45.012mm (1.7719 ~ 1.7721in)
C, 000
45.012 ~ 45.018mm (1.7721 ~ 1.7724in)

Crankshaft Pin Diameter Mark Location

Discrimination Of Crankshaft Pin Diameter
Mark
Crankshaft pin outer diameter
1
41.954 ~ 41.960mm (1.6517 ~ 1.6520in)
2
41.966 ~ 41.960mm (1.6522 ~ 1.6520in)
3
41.960 ~ 41.954mm (1.6520 ~ 1.6517in)

Connecting Rod Bearing Color Location

Discrimination Of Connecting Rod Bearing
Mark
Color
Connecting rod bearing thickness
A
Blue
1.514 ~ 1.517mm (0.0596 ~ 0.0597in)
B
Black
1.511 ~ 1.514mm (0.0595 ~ 0.0596in)
C
None
1.508 ~ 1.511mm (0.0594 ~ 0.0595in)
D
Green
1.505 ~ 1.508mm (0.0593 ~ 0.0594in)
E
Red
1.502 ~ 1.505mm (0.0591 ~ 0.0593in)

(11)
Select the bearing by using selection table.
Connecting Rod Bearing Selection Table

Connecting rod mark
A, 0
B, 00
C, 000
Crank shaft pin journal mark
1
E
(Red)
D
(Green)
C
(None)
2
D
(Green)
C
(None)
B
(Black)
3
C
(None)
B
(Black)
A
(Blue)

3.
Check the 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.

Allowable bend of connecting rod :
0.05mm / 100mm (0.0020in / 3.94in ) or less
Allowable twist of connecting rod :
0.10mm / 100mm (0.0039in / 3.94in) or less

   
When the connecting rods installed without bearings, there should be no difference on side surface.
4.
Check the crankshaft bearing oil clearance.
(1)
To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.
(2)
Clean each main journal and lower bearing with a clean shop towel.
(3)
Place one strip of plastigage across each main journal.
(4)
Reinstall the lower bearings and caps, then tighten 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.
(5)
Remove the cap and lower bearing again, and measure the widest part of the plastigage.

Standard oil clearance :
No.1, 2, 3, 4, 5 : 0.021 ~ 0.042mm (0.0008 ~ 0.0017in)

(6)
If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to crankshaft main bearing selection table in this Group).
Recheck the oil clearance.
   
Do not file, shim, or scrape the bearings or the cap to adjust clearance.
(7)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft main bearing selection table in this Group).
Recheck the oil clearance.
   
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.
Cylinder block crankshaft journal bore mark location
Letters have been stamped on the side surface of the block as a mark (A) for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.

Discrimination Of Cylinder Block Crankshaft Journal Bore
Mark
Cylinder block crankshaft journal bore
inner diameter
A
52.000 ~ 52.006mm (2.0472 ~ 2.0475in)
B
52.006 ~ 52.012mm (2.0475 ~ 2.0477in)
C
52.012 ~ 52.018mm (2.0477 ~ 2.0479in)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal
Mark
Crankshaft main journal
outer diameter
1
47.960 ~ 47.954mm (1.8882 ~ 1.8879in)
2
47.954 ~ 47.948mm (1.8879 ~ 1.8877in)
3
47.948 ~ 47.942mm (1.8877 ~ 1.8875in)

Crankshaft Main Bearing Color Location

Discrimination Of Crankshaft Main Bearing
Mark
Color
Crankshaft main bearing thickness
No.1, 2, 3, 4, 5
A
Blue
2.026 ~ 2.029mm (0.0798 ~ 0.0799in)
B
Black
2.023 ~ 2.026mm (0.0796 ~ 0.0798in)
C
None
2.020 ~ 2.023mm (0.0795 ~ 0.0796in)
D
Green
2.017 ~ 2.020mm (0.0794 ~ 0.0795in)
E
Red
2.014 ~ 2.017mm (0.0793 ~ 0.0794in)

(8)
Select the bearing by using selection table.
Crankshaft Main Bearing Selection Table

Cylinder block crankshaft journal bore mark
A
B
C
Crank shaft main journal mark
1
E
(Red)
D
(Green)
C
(None)
2
D
(Green)
C
(None)
B
(Black)
3
C
(None)
B
(Black)
A
(Blue)

5.
Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

End play
Standard: 0.05 ~ 0.25mm (0.0020 ~ 0.0098in)
Limit : 0.30mm (0.0118in)

If the end play is greater than maximum, replace the center bearing.
Cylinder Block
1.
Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2.
Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3.
Inspect the 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 (0.0020in) for total area
Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in) X 100mm (3.9370in)

4.
Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5.
Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :
77.00 ~ 77.03mm (3.0315 ~ 3.0327in)

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

Discrimination Of Cylinder Bore Size
Mark
Cylinder bore inner diameter
A
77.00 ~ 77.01mm (3.0315 ~ 3.0319in)
B
77.01 ~ 77.02mm (3.0319 ~ 3.0323in)
C
77.02 ~ 77.03mm (3.0323 ~ 3.0327in)

7.
Check the piston size mark (A) on the piston top face.

A : Grade
T : Gasoline engine (T-GDI)
6 : 1.6L
Discrimination Of Piston Outer Diameter
Mark
Piston outer diameter
A
76.97 ~ 76.98mm (3.0303 ~ 3.0307in)
B
76.98 ~ 76.99mm (3.0307 ~ 3.0311in)
C
76.99 ~ 77.00mm (3.0311 ~ 3.0315in)

8.
Select the piston related to cylinder bore class.

Piston -to-cylinder clearance :
0.02 ~ 0.04mm (0.0008 ~ 0.0016in)

Piston And Piston Rings
1.
Clean the 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 12mm(0.4724in) from bottom land of the piston.
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    Standard diameter :
    76.97 ~ 77.00mm (3.0303 ~ 3.0315in)

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