Hyundai Kona: Cylinder Block / Cylinder Block 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 (20°C [68°F]) 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.
  
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.
1.
Remove the engine and transaxle assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2.
Remove the dual clutch transmission.
(Refer to DCT(Dual clutch Transmission) System - "DCT (Dual clutch Transmission)")
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 oil pressure switch.
(Refer to Lubrication System - "Oil Pressure Switch")
13.
Remove the water inlet fitting and thermostat.
(Refer to Cooling System - "Thermostat")
14.
Remove the crankshaft position sensor.
(Refer to Engine Control/Fuel System - "Crankshaft Position Sensor (CKPS)")
15.
Remove the ladder frame.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
16.
Check the connecting rod side clearance.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
17.
Check the connecting rod bearing cap oil clearance.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
18.
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
19.
Check the main bearing oil clearance.
(Refer to Cylinder Block Assembly - "Crankshaft")
20.
Check the crankshaft end play.
(Refer to Cylinder Block Assembly - "Crankshaft")
21.
Remove the crankshaft.
(Refer to Cylinder Block Assembly - "Crankshaft")
22.
Remove the knock sensor.
(Refer to Engine Control/Fuel System - "Knock Sensor (KS)")
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.
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 :
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.
5.
Using the cylinder bore gauge, measure the cylinder bore’s inner diameter to the axial and axial perpendicular directions.
Cylinder bore diameter :
77.00 - 77.03 mm (3.0315 - 3.0327 in)

Reassembly
1.
Install 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 Assembly - "Crankshaft")
Piston selection
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
Crankshaft Repair procedures
Disassembly    • Use fender covers to avoid damaging painted surfaces. ...

Cooling System
...

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