Hyundai Kona: Cylinder Block / Crankshaft Repair procedures

Disassembly
  
Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  
Mark all wiring connector and hoses to avoid misconnection.
Turn the crankshaft damper pulley so that the No.1 piston is at TDC (Top dead center).
1.
Remove the engine and Transaxle Assembly assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2.
Remove the dual clutch transmission.
(Refer to Dual clutch Transmission (DCT) System - "Dual clutch Transmission (DCT)")
3.
Remove the external damper flywheel.
(Refer to Cylinder block - "External Damper Flywheel")
4.
Remove the rear oil seal.
(Refer to Cylinder block - "Rear Oil Seal")
5.
Install the engine to engine stand for disassembly.
6.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
7.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
8.
Remove the timing chain.
(Refet to Timing System - "Timing Chain")
9.
Remove the cylinder head Assembly.
(Refet to Cylindet Head Assembly - "Cylinder Head")
10.
Remove the oil pan and oil screen.
(Refer to Lubrication System - "Oil Pan")
11.
Remove the oil cooler.
(Refer to Lubrication System - "Engine Oil")
12.
Remove the ladder frame.
(Refer to Cylinder Block - "Piston and Connecting Rod")
13.
Remove the piston and connecting rod assembly.
(Refer to Cylinder Block- "Piston and Connecting Rod")
14.
Check the crankshaft main bearing oil clearance.
15.
Remove the main bearing caps (A).

16.
Check the crankshaft end play.
17.
Lift the crankshaft (A) out of the cylinder block, being careful not to damage journals.
  
Arrange the main bearings and thrust bearings in the correct order.
Keep the main bearing caps with their bearings assembled together.

Inspection
1.
Check the crankshaft main bearing oil clearance.
(1)
To check main bearing-to-journal oil clearance, remove the bearing caps with their 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 bearing caps with their lower bearings, then 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°]
  
Do not reuse the crankshaft main bearing cap.
Do not turn the crankshaft.
(5)
Remove the bearing caps with their lower bearing again, and measure the widest part of the plastigage.
Bearing oil clearance :
No.1, 2, 3, 4, 5 : 0.020 - 0.041 mm (0.0007 - 0.0016 in)

(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. Recheck the oil clearance.
  
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. 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 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 - 52.006 mm (2.0472 - 2.0475 in)
B
52.006 - 52.012 mm (2.0475 - 2.0477 in)
C
52.012 - 52.018 mm (2.0477 - 2.0479 in)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal
Mark
Crankshaft main journal outer diameter
A
47.954 - 47.960 mm
(1.8879 - 1.8882 in)
B
47.948 - 47.954 mm
(1.8877 - 1.8879 in)
C
47.942 - 47.948 mm
(1.8875 - 1.8877 in)

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 - 2.029 mm
(0.0798 - 0.0799 in)
B
Black
2.023 - 2.026 mm
(0.0796 - 0.0798 in)
C
None
2.020 - 2.023 mm
(0.0795 - 0.0796 in)
D
Green
2.017 - 2.020 mm
(0.0794 - 0.0795 in)
E
Red / Yellow
2.014 - 2.017 mm
(0.0793 - 0.0794 in)

(8)
Select the bearing by using selection table.
Crankshaft Main Bearing Selection Table
Assembling Classification Of Bearing
Cylinder block crankshaft journal bore mark
A
B
C
Crank shaft main journal mark
1
E
(Red / Yellow)
D
(Green)
C
(None)
2
D
(Green)
C
(None)
B
(Black)
3
C
(None)
B
(Black)
A
(Blue)

2.
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
Standard : 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
Reassembly
  
Thoroughly clean all parts to 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.
Install the crankshaft main bearings.
  
Upper bearings have an oil groove of oil holes ; Lower bearings do not.
(1)
Align the bearing claw with the claw groove of the cylinder block, push in the five upper bearings(A).

(2)
Align the bearing claw with the claw groove of the main bearing cap (B), and push in the 5 lower bearings (A).

(3)
Apply a coat of engine oil after assembling the main bearings.
2.
Install the thrust bearing.
Install the thrust bearing (A) on the No.3 journal position of the cylinder block with the oil grooves facing outward.

3.
Place the crankshaft on the cylinder block.
  
When exchanging the crack shaft and short engine, apply if the pilot bearing is not assembled.
When press fitting the pilot bearing, press fit so that the load is applied only to the outer race of the pilot bearing.
If load is applied to the seal and inner race, the component or bearing inside may be damaged.

Press-fit depth of the pilot bearing: 1.5 - 2.0mm (0.0591 - 0.0787 in) from the end of the crank auto bore.

4.
Install the main bearing caps and tighten the cap bolts.
  
Do not reuse the main bearing cap bolt.
Fasten the main bearing cap bolt in two stages.
Replace the main bearing cap bolt if it is damaged or deformed.
Mount the main bearing cap bolt according to the accurate order.
(1)
Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2)
Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Tightening torque :
[17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft)] + [88 - 92° ]
Using the SST (09221-4A000), tighten the main bearing cap bolts (A).

(3)
Check that the crankshaft turns smoothly.
5.
Check the crankshaft end play.
6.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
7.
Install the ladder frame.
(Refer to Cylinder Block - "Ladder Frame")
8.
Install 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 Assembly - "Piston and Connecting Rod")
Crankshaft Components and components location
Components 1. Crankshaft 2. Crankshaft upper bearing 3. Crankshaft lower bearing 4. Thrust bearing 5. Main bearing cap 6. Crankshaft sproket 7. ...

Cylinder Block Repair procedures
Disassembly    • Use fender covers to avoid damaging painted surfaces. ...

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