Hyundai Genesis: 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.
   
Mark all wiring and hoses to avoid misconnection.
Inspect the timing chain before removing the cylinder head.
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
1.
Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")
2.
Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
3.
Attach the engine to engine stand for disassembly.
4.
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
5.
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
6.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
7.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
8.
Remove the cylinder head.
(Refer to Cylinder Head Assembly - "Cylinder Head")
9.
Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
10.
Remove the oil cover (A) and gasket (B).

11.
Remove the water jacket separator.
(Refer to Cylinder Block - "Water Jacket Separator")
12.
Remove the knock sensor (A).

13.
Remove the upper oil pan.
(Refer to Lubrication System - "Oil Pan")
14.
Remove the baffle plate (A).

15.
Remove the rear oil seal case (A).

16.
Remove the oil drain cover (A) and gasket (B).

17.
Check the connecting rod side clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
18.
Check the connecting rod bearing cap oil clearance.
(Refer to Cylinder Block - "Piston and Connecting Rod")
19.
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.
20.
Remove the crankshaft main bearing cap and check oil clearance.
(Refer to Cylinder Block - "Crankshaft")
21.
Check the crankshaft end play.
(Refer to Cylinder Block - "Crankshaft")
22.
Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")

   
Arrange the main bearings and thrust bearings in the correct order.
23.
Remove the oil jets (A).

24.
Disassemble the piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings (A).
(2)
Remove the oil ring and coil spring (B) by hand.
   
Arrange the piston rings in the correct order only.
25.
Remove the snap rings at both ends of the piston pin, and push the piston pin to disconnect the connecting rod.
Inspection
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 the 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 0.05 mm (0.0020 in.),
Less than 0.02 mm (0.0008 in.) / 150 x 150

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

Standard diameter :
96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)

   
Measuring direction : axial direction, Thrust direction
6.
Check the cylinder bore size code on the cylinder block.

Class
Mark
3.8L
A
A
96.00 ~ 96.01 mm
(3.7795 ~ 3.7799 in.)
B
B
96.01 ~ 96.02 mm
(3.7799 ~ 3.7803 in.)
C
C
96.02 ~ 96.03 mm
(3.7803 ~ 3.7807 in.)


The maximum allowable size
96.28 mm (3.7905 in.)

Cylinder boring
1.
Oversize pistons should be selected according to the largest bore cylinder.
Identification Mark
Size
0.1
0.1 mm (0.004 in)
0.25
0.25 mm (0.010 in)

   
The size of piston is stamped on top of the piston.
2.
Measure the outside diameter of the piston to be used.
3.
According to the measured O.D(Outer Diameter), calculate the new bore size.

New bore size = piston O.D + 0.03 to 0.05 mm (0.0012 to 0.0020 in) (clearance between piston and cylinder) - 0.01 mm (0.0004 in) (honing margin.)

4.
Bore each of the cylinders to the calculated size.
   
To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5.
Hone the cylinders for the proper clearance (between the cylinder and piston).
6.
Check the clearance between the piston and cylinder.

Standard : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in)

   
When boring the cylinders, finish all of the cylinders to the same new bore size. Do not bore only one cylinder to the new bore size.
Reassembly
1.
Install the oil jets (A).

Tightening torque
27.5 ~ 31.3 N.m (2.8 ~ 3.2kgf.m, 20.2 ~ 23.1lb-ft)

2.
Install the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
3.
Install the crankshaft main bearing cap and check oil clearance.
(Refer to Cylinder Block - "Crankshaft")
4.
Check the crankshaft end play.
(Refer to Cylinder Block - "Crankshaft")
5.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting rod")
6.
Check the connecting rod end play.
(Refer to Cylinder Block - Piston and Connecting Rod")
7.
Install the plug bolt (A) and the washer gasket (B).

Tightening torque :
83.4 ~ 102.9N.m (8.5 ~ 10.5kgf.m, 61.5 ~ 75.9lb-ft)

8.
Install the rear oil seal case (A).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   
Clean the sealing face before assembling two parts.
Remove harmful foreign materials on the sealing face before applying sealant
Before assembling rear oil seal case, the liquid sealant THREE BOND 1217H should be applied to the rear oil seal case.
The assembly must be done within 5 minutes after the sealant is applied.
Apply sealant to the inner threads of the bolt holes.

9.
Install the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
10.
Install the baffle plate.
When installing the baffle plate bolts, tighten the bolts in two or three steps according to the sequence shown below.

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

11.
Install the upper oil pan.
(Refer to Lubrication System - "Oil Pan")
12.
Install the knock sensor #1 and #2.
(Refer to Engine Control / Fuel System - "Knock Sensor")
13.
Install the water jacket separator.
(Refer to Cylinder Block - "Water Jacket Separator")
14.
Install the oil cover (A) and gasket (B).

Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

15.
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 Block Components and Components Location
Components 1. Water jacket separator 1#2. Water jacket separator 2#3. Cylinder block4. Oil cover 5. Oil cover gasket6. Plug bolt7. Washer gasket ...

Cooling System
...

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