Hyundai Santa Fe (TM): Cylinder Block

Hyundai Santa Fe TM 2019-2023 Service Manual / Engine Mechanical System / Cylinder Block

Drive Plate. Repair procedures

Removal and Installation

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the automatic transaxle . (Refer to Automatic Transaxle System - "Automatic Transaxle")

Remove the drive plate (A) and the adapter plate (B).

Tightening torque :

127.5 - 137.3 N.m (13.0 - 14.0 kgf.m, 94.0 - 101.3 lb-ft)

•	Always use new drive plate (or flywheel) bolts.

•

Apply sealant to the screw part (10mm from the end of the bolt) when reusing the drive plate bolts.

Sealant : MS721 - 39, D

•	Install and uniformly tighten the 7 bolts, in several passes.

3.	Install in the reverse order of removal.

Rear Oil Seal. Repair procedures

Removal

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

1.	Remove the automatic transaxle. (Refer to Automatic Transaxle System - "Automatic Transaxle")

2.	Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")

3.	Rmove the rear oil sela (A).

Installation

Install rear oil seal.

(1)	Apply engine oil to a new oil seal lip.

(2)	Using SST (09231-H1100, 09214 - L1200) (B) and a hammer, tap in the oil seal (A) until its surface is flush with the rear oil seal retainer edge.

2.	Install the drive plate. (Refer to Cylinder Block - "Drive Plate")

3.	Install the automatic transaxle. (Refer to Automatic Transaxle System - "Automatic Transaxle")

Piston and Connecting Rod. Components and components location

Components

1. Piston ring
2. Snap ring
3. Piston
4. Connecting rod

5. Connecting rod upper bearing
6. Connecting rod lower bearing
7. Connecting rod bearing cap

Piston and Connecting Rod. Repair procedures

Disassembly

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

•	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.

•	Turn the crankshaft pulley so that the No.1 piston is at top dead center.

•	Engine removal is required for this procedure.

1.	Remove the engine and transaxle assembly. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")

2.	Remove the harness clamp from the wiring connector around the engine and transaxle and remove the connector bracket.

3.	Remove the automatic transaxle . (Refer to Automatic Transaxle System - "Automatic Transaxle")

4.	Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")

5.	Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")

6.	Install the engine assembly to engine stand for disassembly.

7.	Remove the oil pan. (Refer to Lubrication System - "Oil Pan")

8.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

9.	Remove the intake manifold. (Refer to Intake and Exhaust System - "Intake Manifold")

10.	Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")

11.	Remove the cylinder head. (Refer to Cylinder Head Assembly - "Cylinder Head")

12.	Remove the water jacket insert. (Refer to Cylinder Block - "Water Jacket Insert")

13.	Remove the oil cooler & filter. (Refer to Lubrication System - "Oil Cooler & Filter")

14.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

15.	Remove the A/C compressor. (Refer to Heateng, Ventilation, Air conditioning - "Compressor")

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

17.	Remove the oil pump. (Refer to Lubrication System - "Oil Pump")

18.	Remove the balance shaft module. (Refer to Lubrication system - "Balance Shaft Module")

19.

Remove the piston and connecting rod assembly.

(1)	Remove all the carbon from the top of the cylinder.

(2)

Remove the connecting rod bearing caps (A).

•	Mark the connecting rod, and caps to be able to reassemble in the original position and direction.

(3)

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

•	Keep the connecting rod ands cap with their bearings assembled together.

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

20.	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 piston pin as a set.

21.

Disassemble the piston rings.

(1)	Using a piston ring expender, remove the 2 piston rings (A).

(2)	Remove the oil ring (B) by hand.

22.

Disassemble the connecting rod from the piston.

(1)	Remove the snap ring (C) from the piston.

(2)	Using a press, remove the piston pin (D) from the piston.

(3)	Disassemble the piston (E) and connecting rod (F).

Inspection

Connecting Rod

Check the connecting rod end play.

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

End play :

Standard : 0.10- 0.25 mm (0.0039 - 0.0098 in.)

Limit : 0.35 mm (0.0138 in.)

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

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

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 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-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 :

0.032 - 0.050 mm (0.0013 - 0.0020 in.)

(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.

•	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 Identification Mark

Connecting Rod Specifications

Class	Mark	Inside Diameter
0	A	51.000 - 51.006 mm (2.00787 - 2.00811 in.)
1	B	51.006 - 51.012 mm (2.00811 - 2.00834 in.)
2	C	51.012 - 51.018 mm (2.00834 - 2.00858 in.)

Crankshaft Pin Outside Diameter Identification Mark

Identification Of Crankshaft Pin Outside Diameter

Class	Mark	Crankshaft pin journal outer diameter
A	1	47.966 - 47.972 mm (1.8884 - 1.8887 in.)
B	2	47.960 - 47.966 mm (1.8882 - 1.8884 in.)
C	3	47.954 - 47.960 mm (1.8879 - 1.8882 in.)

Connecting Rod Bearing Identification Mark

Discrimination of Connecting Rod Bearing

Class	Color	Connecting rod bearing thickness
A	LIGHT BLUE	1.507 - 1.510 mm (0.0593 - 0.0594 in.)
B	BLACK	1.504 - 1.507 mm (0.0592 - 0.0593 in.)
C	WHITE	1.501 - 1.504 mm (0.0591 - 0.0592 in.)
D	LIGHT GREEN	1.498 - 1.501 mm (0.0590 - 0.0591 in.)
E	PINK	1.495 - 1.498 mm (0.0589 - 0.0590 in.)

(11)

Use the bearing selection table below to select a suitable connecting rod bearing.

Connecting Rod Bearing Selection Table

SHAFT (CLASS. MARK)	Bore (CLASS. MARK)	Bearing Grade For Installing
I (1)	a (A)	E (PINK)
	b (B)	D (LIGHT GREEN)
	c (C)	C (WHITE)
II (2)	a (A)	D (LIGHT GREEN)
	b (B)	C (WHITE)
	c (C)	B (BLACK)
III (3)	a (A)	C (WHITE)
	b (B)	B (BLACK)
	c (C)	A (LIGHT BLUE)

Inspect 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

Allowable bend of connecting rod :

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

Allowable twist of connecting rod :

0.10mm (0.0039 in.) or less for 100mm (3.94 in.)

Piston

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.

Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance :

0.04 - 0.06 mm (0.0016 - 0.0024 in.)

(1)

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

Cylinder bore diameter :

88.50 - 88.53 mm (3.4842 - 3.4854 in.)

(2)

Measure the piston outside diameter at 13.0 mm (0.5118 in.) from top land of the piston.

Piston outside diameter :

88.45 - 88.48 mm (3.4823 - 3.4835 in.)

Select the piston matching with cylinder bore class.

Piston-to-cylinder clearance :

0.04 - 0.06 mm (0.0016 - 0.0024 in.)

(1)

Check the cylinder bore size mark on the side of the cylinder block.

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 Bore Size

Class	Mark	Cylinder bore inner diameter
a	A	88.50 - 88.51 mm (3.4842 - 3.4846 in.)
b	B	88.51 - 88.52 mm (3.4846 - 3.4850 in.)
c	C	88.52 - 88.53 mm (3.4850 - 3.4854 in.)

(2)

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

Discrimination of Piston Outer Diameter

Mark	Piston outer diameter
A	88.45 - 88.46 mm (3.4823 - 3.4827 in.)
B	88.46 - 88.47 mm (3.4827 - 3.4831 in.)
C	88.47 - 88.48 mm (3.4831 - 3.4835 in.)

Piston Rings

Inspect the piston ring side clearance.

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

Piston ring groove width dimension of piston

No.1 ring :

1.258 - 1.268 mm (0.0495 - 0.0499 in.) (Befor ANODIZING)

1.235 - 1.250 mm (0.0486 - 0.0492 in.) (After ANODIZING)

No.2 ring : 1.230 - 1.250 mm (0.0484 - 0.0492 in.)

Oil ring : 2.010 - 2.025 mm (0.0791 - 0.0797 in.)

Piston ring width dimension

No.1 ring : 1.17 - 1.19 mm (0.0461 - 0.0469 in.)

No.2 ring : 1.17 - 1.19 mm (0.0461 - 0.0469 in.)

Oil ring : 1.91 - 1.97 mm (0.0752 - 0.0776 in.)

Inspect the 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 specifications, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter.

Piston ring end gap

[Standard]

No.1 ring : 0.14 - 0.19 mm (0.0055 - 0.0075 in.)

No.2 ring : 0.30 - 0.40 mm (0.0118 - 0.0157 in.)

Oil ring : 0.10 - 0.40 mm (0.0039 - 0.0157 in.)

Piston Pin

Measure the diameter of the piston pin.

Piston pin diameter :

19.997 - 20.000mm (0.7873 - 0.7874 in.)

Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :

0.003 - 0.010 mm (0.00012 - 0.00039 in.)

Check the difference between the piston pin diameter and the connecting rod bushing oil clearance.

Piston pin-to-connecting rod interference :

0.005 - 0.014 mm (0.00020 - 0.00055 in.)

Reassembly

•	Thoroughly clean all parts to assembled.

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

•	Always use new gaskets, O-ring and oil seals.

Assemble the piston and the connecting rod.

(1)	Install the snap ring (A) in one side of the piston pin hole.

(2)	Align the piston front mark (A) and the connecting rod front mark (B).

(3)	Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod.

(4)

Install the snap ring (B) in the other side after inserting the piston pin.

•	Before inserting the piston pin, apply sufficient engine oil on the piston’s outer surface, piston hole’s inner surface and connecting rod’s small-end bore.

•	When inserting, use caution not to damage or scratch the connecting rods’ small-end hole, piston’s pin hole and piston pin.

•	Install the snap ring surely so that the snap ring contacts the overall groove of the piston’s pin hole.

•	Assemble so that the cut surface of the snap ring is located within the upper 45° range.

Install the piston rings.

(1)	Install the oil ring expander and two side rails by hand.

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

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

Install the connecting rod bearings.

(1)	Align the bearing (B) claw with the groove of the connecting rod or bearing cap (A).

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

Install the piston and connecting rod assembly.

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

•	The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the engine.

(1)	Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.

(2)

Stop after the ring compressor pops free, and check the connecting rod-to-crank 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.

(3)

Install the connecting rod caps (A) with bearings, and tighten the bolts.

Tightening torque

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

•	Always use new connecting rod cap bolts.

5.	Assemble the other parts in the reverse order of disassembly.

Crankshaft. Components and components location

Components

1. Crankshaft upper bearing
2. Thrust bearing
3. Crankshaft
4. Crankshaft lower bearing

5. Crankshaft sprocket
6. Crankshaft position sensor wheel
7. Lower crankcase

Crankshaft. Repair procedures

Disassembly

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

•	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.

•	Turn the crankshaft pulley so that the No.1 piston is at top dead center.

•	Engine removal is required for this procedure.

1.	Remove piston and connecting rod assemblies. (Refer to Cylinder Block - "Piston and Connecting Rod")

Remove the lower crankcase.

(1)	Remove the lower crankcase mounting bolts (A).

(2)	Remove the crankshaft bearing cap bolts (A).

(3)	Remove the lower crankcase (A).

3.	Lift the crankshaft (A) out of the engine block, be careful not to damage journals.

4.	Remove the crankshaft position sensor wheel (A).

Inspection

Check the crankshaft bearing oil clearance.

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

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

(3)

Reinstall the bearing caps with lower bearings, and then tighten the bolts.

Tightening torque :

Crank lower case mounting bolts :

29.4 - 33.3 N.m (3.0 - 3.4 kgf.m, 21.6 - 24.5 Ib-ft)

Bearing cap mounting bolts :

27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 120 - 125°

Crank lower case mounting bolts :

Bearing cap mounting bolts :

•	Do not turn the crankshaft.

(4)

Remove the lower crankcase, and measure the widest part of the plasticgauge.

Bearing oil clearance :

#1,2,4,5 : 0.022~0.040mm (0.00086 - 0.00157 in.)

#3 : 0.028~0.046mm (0.00110 - 0.00181 in.)

(5)

If the plasticgauge measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark (select the color as shown in the next column). Recheck the oil clearance.

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

(6)

If the plasticgauge shows that 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.

Cylinder Block Crankshaft Journal Bore Mark Location

Letters have been stamped on the side surface of the block as a mark 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.

Class	Mark	Cylinder block crankshaft journal bore inner diameter
a	A	57.000 - 57.006 mm (2.2441 - 2.2443 in.)
b	B	57.006 - 57.012 mm (2.2443 - 2.2446 in.)
c	C	57.012 - 57.018 mm (2.2446 - 2.2448 in.)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal

Class	Mark	Crankshaft main journal outer diameter
A	1	51.954 - 51.960 mm (2.0454 - 2.0457 in.)
B	2	51.948 - 51.954 mm (2.0452 - 2.0454 in.)
C	3	51.942 - 51.948 mm (2.0450 - 2.0452 in.)

Crankshaft Bearing Identification Mark Location

[No. 2, No 3, No. 4 Journal Upper Bearing]

[No. 1, No 5 Journal Upper Bearing]

[Lower Bearing]

Discrimination Of Crankshaft Bearing

Class	Color	Bearing thickness
A	LIGHT Blue	2.518 - 2.521mm (0.0991 - 0.0993in.)
B	Black	2.515 - 2.518mm (0.0990 - 0.0991in.)
C	WHITE	2.512 - 2.515mm (0.0989 - 0.0990in.)
D	LIGT GREEN	2.509 - 2.512mm (0.0988 - 0.0989in.)
E	PINK	2.506 - 2.509 mm (0.0987 - 0.0988 in.)
F	YELLOW	2.503 - 2.506 mm (0.0985 - 0.0987 in.)

(7)

Select the bearing by using selection table.

Crankshaft Main Bearing Selection Table

Crank Shaft Journal & Cylinder Block Bore		Bearing Grade For Installing
Crank Shaft Class Mark	Cylinder Block Bore Mark	#1, 2, 4, 5 Journal	#3 Journal
I (1)	a (A)	E ( PINK)	F (YELLOW)
	b (B)	D (LIGHT GREEN)	E ( PINK)
	c (C)	C (WHITE)	D (LIGHT GREEN)
I (2)	a (A)	D (LIGHT GREEN)	E ( PINK)
	b (B)	C (WHITE)	D (LIGHT GREEN)
	c (C)	B (BLACK)	C (WHITE)
I (3)	a (A)	C (WHITE)	D (LIGHT GREEN)
	b (B)	B (BLACK)	C (WHITE)
	c (C)	A (LIGHT BLUE)	B (BLACK)

Check the crankshaft end play.

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

Crankshaft end play

0.100 - 0.280 mm (0.0039 - 1.0110 in.)

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

Thickness of thrust bearing :

2.41 - 2.45 mm (0.0948 - 0.9645 in.)

Inspect the crankshaft main journals and pin journals.

Using a micrometer, measure the diameter of each main journal and pin journal.

Main journal diameter :

51.942 - 51.960 mm (2.0450 - 2.0457 in.)

Crank pin diameter :

47.954 - 47.972 mm (1.8879 - 1.8887 in.)

Reassembly

•	Thoroughly clean all parts to assembled.

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

•	Always use new gaskets, O-ring and oil seals.

Install the crankshaft position sensor wheel (A).

Tightening torque :

26.5 - 27.5 N.m (2.7 - 2.8 kgf.m, 19.5 - 20.3 lb-ft)

•	Set the crankshaft position sensor wheel mark (Rear) so that it faces rear.

Install the main bearing.

•	When installing the crankshaft upper bearings, the upper bearings should fit for each journal. [No. 2, No 3, No. 4 Journal Upper Bearing] [No. 1, No 5 Journal Upper Bearing]

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

(2)	Align the bearing claw with the groove of the crank lower case, and push in the 5 lower bearings (A).

(3)	Apply a coat of engine oil after assembling the main bearings.

3.	Install the thrust bearings. Install the 2 thrust bearings (A) on both sides of the No.4 journal of the cylinder block with the oil groove facing out.

4.	Install the crankshaft (A) on the cylinder block.

Install the lower crankcase.

(1)	Make sure to remove hardened sealant, foreign matters, oil, dust, moisture on the sealing face of the liquid gasket of the lower crankcase. Spray the cleaner on the sealing surface and wipe it off with a clean cloth.

(2)	Install the new O-ring (A) on the cylinder block.

(3)	Apply liquid sealant on lower crankcase. Then, assemble the part within 5 minutes of applying sealant.

(4)

Tighten the crankshaft bearing cap bolts several times according to the tightening sequence shown below.

Tightening torque

27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 120 - 125°

•	Always use new bearing cap bolts.

(5)

Tighten the lower crankcase mounting bolts several times according to the tightening sequence shown below.

Tightening torque :

29.4 - 33.3 N.m (3.0 - 3.4 kgf.m, 21.6 - 24.5 Ib-ft)

(6)	Check that the crankshaft turns smoothly.

6.	Check the crankshaft end play.

7.	Install the piston and connecting rod assemblies. (Refer to Cylinder Block - "Piston and Connecting Rod")

Assemble the other parts in the reverse order of disassembly.

•	In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft.

•	Connecting rod bearing selection (Refer to Cylinder Block - "Piston and Connecting Rod")

Cylinder Block. Repair procedures

Disassembly

•	Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift. (Refer to General Information - "Lift and Support Points")

•	Use fender covers to avoid damaging painted surfaces.

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

•	Mark all wiring connector and hoses to avoid misconnection.

•	To release the fuel system pressure before removing the engine assembly, start the engine without fuel pump relay. Then, switch "OFF" the ignition when engine stops.

•	Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1.	Remove the crankshaft. (Refer to Cylinder Block - "Crankshaft")

2.	Remove the knock sensor. (Refer to Engine Control / Fuel System - "Knock Sensor (KS)")

3.	Remove the crankshaft position sensor (CKPS). (Refer to Engine Control / Fuel System - "Crankshaft Position Sensor (CKPS)")

4.	Remove the piston cooling oil jets (A).

Inspection

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

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

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 :

Less than 0.05 mm (0.0020 in.) for total area

Less than 0.02 mm (0.0008 in.) for a section of 100 mm x 100 mm (3.9370 in x 3.9370 in.)

4.	Visually check for scratches on the inside surface of the cylinder bore and replace the cylinder block if any noticeable scratch is detected. If deep scratchs are present, replace the cylinder block.

Using the cylinder bore gauge, measure the cylinder bore’s inner diameter to the axial and axial perpendicular directions.

Cylinder bore diameter :

88.50 - 88.53 mm (3.4842 - 3.4854 in.)

Reassembly

•	Thoroughly clean all parts to assembled.

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

•	Always use new gaskets, O-ring and oil seals.

Install the piston cooling oil jets (A).

Tightening torque :

8.8 - 10.8 N.m (0.9 - 1.1 kgf.m, 6.5 - 8.0 lb-ft)

2.	Install the crankshaft. (Refer to Cylinder Block - "Crankshaft")

3.	Check the crankshaft end play. (Refer to Cylinder Block - "Crankshaft")

4.	Disconnect the lower crankcase and check crankshaft bearing oil clearance. (Refer to Cylinder Block - "Crankshaft")

5.	Install the piston and connecting rod assembly. (Refer to Cylinder Block - "Piston and Connecting Rod")

6.	Check the connecting rod bearing cap oil clearance. (Refer to Cylinder Block - "Piston and Connecting Rod")

7.	Check the connecting rod end play. (Refer to Cylinder Block - "Piston and Connecting Rod")

Assemble the other parts in the reverse order of disassembly.

•	In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block.

•	Crankshaft main bearing selection (Refer to Cylinder Block - "Crankshaft")

•	Piston selection (Refer to Cylinder Block - "Piston and Connecting Rod")

Cylinder Head Assembly

Components and components location Components 1. Camshaft front bearing cap 2. Camshaft bearing cap 3. OCV & Center bolt 4. Exhaust CVVT assembly 5. Exhaust camshaft 6. Intake camshaft 7. Intake CVVT ...

Cooling System

Coolant. Repair procedures Refilling And Bleeding • Never remove the reservoir tank cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping ...