Hyundai Genesis: Cylinder Block / 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.
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 the gasket (B).

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

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 plug bolt (A) and a washer gasket (B).

17.
Check the connecting rod cap oil clearance.
18.
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.
19.
Remove the crankshaft bearing cap and check oil clearance.
20.
Check the crankshaft end play.
21.
Remove the crankshaft (A).

   
Arrange the main bearings and thrust bearings in the correct order.
22.
Remove the oil jets (A).

23.
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
24.
Remove the snap rings at both ends of the piston pin, and push the piston pin to disconnect the connecting rod.
Inspection
Connecting Rod
1.
Check the connecting rod side clearance.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1 ~ 0.25 mm (0.004 ~ 0.010 in.)

A.
If the side clearance is out of tolerance, install a new connecting rod.
B.
If the crankshaft is still out of tolerance after connecting rod replacement, replace the crankshaft.
2.
Check the connecting rod bearing oil clearance.
(1)
Check the match marks 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 crankshaft pin journal and bearing.
(5)
Place plastigage across the crank pin.
(6)
Reinstall the bearing half and cap, and tighten the bolts with the specified torque.

Tightening torque:
[27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)] + [68 ~ 72°]

   
Do not turn the crankshaft.
(7)
Remove the connecting rod cap again.
(8)
Measure the plastigage at its widest point.

Standard oil clearance:
0.028 ~ 0.046 mm (0.0011 ~ 0.0018 in.)

(9)
If the plastigage measurement is 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 orbelow 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 Mark Location

Identification of Connecting Rod
Class
Mark
Inside Diameter
0
a
58.000 ~ 58.006 mm
(2.2834 ~ 2.2837 in.)
1
b
58.006 ~ 58.012 mm
(2.2837 ~ 2.2839 in.)
2
c
58.012 ~ 58.018 mm
(2.2839 ~ 2.2842 in.)

Crankshaft Pin Mark Location
Identification of Crankshaft

Discrimination of Crankshaft
Class
Mark
Outside Diameter Of Pin
I
1 or A
54.966 ~ 54.972 mm
(2.1640 ~ 2.1642 in.)
II
2 or B
54.960 ~ 54.966 mm
(2.1638 ~ 2.1640 in.)
III
3 or C
54.954 ~ 54.960 mm
(2.1635 ~ 2.1638 in.)

Place of Identification Mark (Connecting Rod Bearing)

Identification of Connecting Rod Bearing
Class
Mark
Thickness Of Bearing
E
BLUE
1.509 ~ 1.512
(0.05941 ~ 0.05953 in)
D
BLACK
1.506 ~ 1.509
(0.05929 ~ 0.05941 in)
C
RED
1.503 ~ 1.506
(0.05917 ~ 0.05929 in)
B
GREEN
1.500 ~ 1.503
(0.05906 ~ 0.05917 in)
A
YELLOW
1.497 ~ 1.500
(0.05894 ~ 0.05906 in)

(11)
Selection
?
Connecting Rod Identification Mark
0(a)
1(b)
2(c)
Crankshaft Indentification Mark
1 or A
A
(YELLOW)
B
(GREEN)
C
(RED)
2 or B
B
(GREEN)
C
(RED)
D
(BLACK)
3 or C
C
(RED)
D
(BLACK)
E
(BLUE)

3.
Check the connecting rod.
(1)
When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
(2)
If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
(3)
Using a connecting rod aligner, measure the degree of bending or torsion of the rod. If the measured value is not within the specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it.

Allowable bend of connecting rod:
0.05 mm/100 mm (0.0020 in./3.9370 in.)
Allowable twist of connecting rod:
0.1 mm/100 mm (0.0039 in./3.9370 in.)

   
When assembling the rod without a bearing, there should be no difference.
Piston
1.
Clean piston
(1)
Using a gasket scraper, remove the carbon from the piston top.
(2)
Using a groove cleaning tool, clean the piston ring grooves.
(3)
Using solvent and a brush, thoroughly clean the piston.
   
Do not use a wire brush.
2.
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 :
0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in)

(1)
Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

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

(2)
Measure the piston outside diameter at 3.8L : 16 mm (0.6299 in.) from bottom land of the piston.

Standard diameter :
95.96 ~ 95.99 mm (3.7779 ~ 3.7791 in.)

3.
Select the piston matching with cylinder bore class.

Piston-to-cylinder clearance :
0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)

(1)
Check the cylinder bore size mark code on the cylinder block side surface.

Discrimination of Cylinder Bore Size
Class
Size code
Cylinder bore inner diameter
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.)

(2)
Check the piston size code (A) and the front mark (B) on the piston top face.

Discrimination of Piston Outer Diameter
Class
Mark
3.8L
A
A
95.96 ~ 95.97 mm (3.7779 ~ 3.7783 in.)
B
B
95.97 ~ 95.98 mm (3.7783 ~ 3.7787 in.)
C
C
95.98 ~ 95.99 mm (3.7787 ~ 3.7791 in.)

Piston Rings
1.
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove.

Piston ring side clearance
Standard
No.1 : 0.06 ~ 0.09 mm (0.0024 ~ 0.0035 in.)
No.2 : 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.)
Oil ring : 0.02 ~ 0.065 mm (0.0008 ~ 0.0026 in.)
Limit
No.1 : 0.1 mm (0.0039 in.)
No.2 : 0.1 mm (0.0039 in.)
Oil ring : 0.2 mm (0.0079 in.)

If the clearance is greater than the maximum limit, replace the piston.
2.
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at the right angle 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 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)
No.2 : 0.32 ~ 0.47mm (0.0126 ~ 0.0185 in.)
Oil ring : 0.2 ~ 0.5mm (0.0079 ~ 0.0197in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

Piston Pins
1.
Measure the external diameter of the piston pin.

Piston pin diameter :
21.097 ~ 22.000mm (0.8306 ~ 0.8661 in.)

2.
Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :
0.004 ~ 0.013 mm (0.0002 ~ 0.0005 in.)

3.
Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference :
0.005 ~ 0.019 mm (0.0002 ~ -0.0007 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 the connecting rod.
(1)
Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly.
(2)
The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.

2.
Install the piston rings.
(1)
Install the coil spring and oil ring by hand.
(2)
Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3)
Install the piston rings to ensure the ring ends are positioned as shown below.

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).

   
When reassembling the connecting rods and the caps, make sure that each connecting rod and connecting cap are placed in their original position.
4.
Install the piston and connecting rod assemblies.
   
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1)
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.
(2)
Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
(3)
Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

Tightening torque :
[27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)] + [68 ~ 72°]

   
Always use new connecting rod cap bolts. Connecting rod cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.

   
Use SST (09221-4A000), install connecting rod bearing cap bolts.

5.
Install the connecting rod caps and check oil clearance.
6.
Check the connecting rod end play.
7.
Install the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
8.
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)

9.
Assemble the other parts in the reverse order of disassembly.
Piston and Connecting Rod Components and Components Location
Components 1. Piston ring2. Piston pin3. Snap ring4. Piston5. Connecting rod6. Connecting rod upper bearing7. Connecting rod lower bearing8. Connecting rod bearing cap ...

Crankshaft Components and Components Location
Components 1. Crank shaft upper bearing2. Thrust bearing3. Crankshaft4. Crankshaft lower bearing5. Main bearing cap ...

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