Hyundai Santa Fe (DM): Piston and Connecting Rod. Repair procedures - Cylinder Block - Engine Mechanical SystemHyundai Santa Fe (DM): Piston and Connecting Rod. Repair procedures

Disassembly

•
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.
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
1.
Remove the ladder frame.
2.
Check the connecting rod end play.
3.
Remove the connecting rod caps and check oil clearance.
4.
Remove 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.
5.
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.
6.
Remove piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings.
(2)
Remove oil ring.
Arrange the piston rings in the correct order only.

Inspection

Connecting Rod
1.
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.)

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
A type :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°
B type :
17.7~21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 78 ~ 82°
A Type
 B Type


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 :
0.033 ~ 0.051 mm (0.00130 ~ 0.00201 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
a
 A
 51.000 ~ 51.006 mm
(2.00787 ~ 2.00811 in.)
b
 B
 51.006 ~ 51.012 mm
(2.00811 ~ 2.00834 in.)
c
 C
 51.012 ~ 51.018 mm
(2.00834 ~ 2.00858 in.)

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 17 mm (0.67 in.) from the top land of the piston.
Standard diameter :
87.970 ~ 88.000 mm (3.46338 ~ 3.46456 in.)

3.
Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance :
0.020 ~ 0.040 mm (0.00079 ~ 0.00157 in.)
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.
Piston ring side clearance
Standard
No.1 : 0.050 ~ 0.080 mm (0.00197 ~ 0.00315 in.)
No.2 : 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring : 0.020 ~ 0.055 mm (0.00079 ~ 0.00217 in.)
Limit
No.1 : 0.100 mm (0.00394 in.)
No.2 : 0.100 mm (0.00394 in.)
Oil ring : 0.60 mm (0.0236 in.)

If the clearance is greater than maximum, replace the piston.
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 replaced.
Piston ring end gap
Standard
No.1 : 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in.)
No.2 : 0.37 ~ 0.47 mm (0.0145 ~ 0.0185 in.)
Oil ring : 0.20 ~ 0.50 mm (0.0079 ~ 0.0197 in.)
Limit
No.1 : 0.60 mm (0.0236 in.)
No.2 : 0.70 mm (0.0275 in.)
Oil ring : 0.80 mm (0.0315 in.)

Piston Pins
1.
Measure the diameter of the piston pin.
Piston pin diameter :
21.997 ~ 22.000 mm (0.86602 ~ 0.86614 in.)

2.
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance :
0.003 ~ 0.010 mm (0.00012 ~ 0.00039 in.)
3.
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 be 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 chain side of the engine.
(2)
Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
•
Take care that piston pin is not damaged during reassemble .
•
When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.
Piston pin outer diameter : 21.997 ~ 22.000 mm (0.8660 ~ 0.8661 in)
Piston pin hole inner diameter : 22.003 ~ 22.007 mm (0.8662 ~ 0.8664 in)
Connecting rod small end inner diameter : 22.005 ~ 22.011 mm (0.8663 ~ 0.8665 in)
Interference : -0.014 ~ -0.005 mm (0.0006 ~ 0.0002 in)
(3)
Set the snap ring in one side of piston pin hole and insert the piston pin into the piston pin hole & the small end bore of connecting rod while meeting the front mark of connecting rod & piston.
Be sure to keep the small end bore, pistonpin hole & piston pin from being damaged and scratched when inserting the piston pin.
Assembling condition
Temperature : piston side 70 to 80C , connecting rod & pin is to be normal room temperature.
(4)
After inserting the piston pin, set the snap ring of the other side.
Set the snap ring so that it contacts completely with the groove of the piston pin hole.
The snap ring must not be deformed from the installation tooling method.
2.
Install the piston rings .
(1)
Install the oil ring with coil spring 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.
Remove the crankshaft.
(Refer to Cylinder Block - "Crandshaft")
5.
Install 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.
(4)
Apply engine oil to the bolt threads. Using the SST (09221-4A000), install the rod caps with bearings, and torque the bolts.
Tightening torque
A type :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°
B type :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 78 ~ 82°
A Type
 B Type


Always use new connecting rod cap bolts.
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.


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