Hyundai i-30: Cylinder Block / Crankshaft

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft

Components and components location
Components

1. Thrust bearing
2. Upper main bearing
3. Crankshaft
4. Lower main bearing
5. Main bearing cap

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 and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No.1 piston is at TDC (Top dead center).
1.
Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2.
Remove the transaxle assembly from the engine assembly.
(Refer to Double Clutch Transmission (DCT) System - "Double Clutch Transmission (DCT)")
3.
Remove the flywheel.
(Refer to Cylinder Block - "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 timing chain.
(Refer to Timing System - "Timing Chain")
7.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
8.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhayst Manifold")
9.
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
10.
Remove the A/C compressor.
(Refer to Heating, Ventilation Air conditioning - "Compressor")
11.
Remove the inlet fitting.
(Refer to Cooling System - "Inlet Fitting")
12.
Remove the knock sensor.
(Refer to Engine Control / Fuel System - "Knock Sensor")
13.
Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")s
14.
Remove the ladder frame.
(Refer to Cylinder Block - "Cylinder Block")
15.
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
16.
Remove the main bearing caps and check oil clearance.
17.
Check the crankshaft end play.
18.
Lift the crankshaft (A) out of engine, being careful not to damage journals.

  
Arrange the main bearings and thrust bearings in the correct order.
Inspection
1.
Check the crankshaft bearing oil clearance.
(1)
To check main bearing-to-journal oil clearance, remove the main bearings.
(2)
Clean each main journal and bearing half with a clean shop tower.
(3)
Place one strip of plastigage across each main journal.
(4)
Use the SST (09221-4A000), reinstall the bearings and bolts as following method with specified torque. In the sequence.
Tightening torque :
17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 108 - 112°

  
Do not turn the crankshaft.
Always use new main bearing cap bolts.
(5)
Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance :
No. 1,2,4,5 journal : 0.012 - 0.030 mm (0.0005 - 0.0012 in.)
No. 3 journal : 0.018 - 0.036 mm (0.0007 - 0.0014 in.)

(6)
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.
(7)
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.
Cylinder block crankshaft journal bore mark location
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.

Grade
Mark
Cylinder Block Crankshaft journal Bore Inner Diameter
a
A
52.000 - 52.006 mm
(2.0472 - 2.0475 in)
b
B
OVER 52.006 - TO 52.012 mm
(OVER 2.0475 - TO 2.0477 in)
c
C
OVER 52.012 - TO 52.018 mm
(OVER 2.0477 - TO 2.0480 in)

Crankshaft Main Journal Mark Location

Discrimination of Crankshaft Main Journal
Class
Mark
Crankshaft main journalouter diameter
I
1
47.954 - 47.960 mm
(1.8879 - 1.8881 in)
II
2
47.948 - 47.954 mm
(1.8877 - 1.8879 in)
III
3
47.942 - 47.948 mm
(1.8874 - 1.8877 in)

Crankshaft Main Bearing Mark Location

Mark
Color
Crankshaft Main Bearing Thickness
1
Blue
2.023 - 2.026 mm(0.0796 - 0.0797 in)
2
Black
2.020 - 2.023 mm(0.0795 - 0.0796 in)
3
None
2.017 - 2.020 mm(0.0794 - 0.0795 in)
4
Green
2.014 - 2.017 mm(0.0792 - 0.0794 in)
5
Yellow
2.011 - 2.014 mm(0.0791 - 0.0792 in)
6
Red
2.008 - 2.011 mm (0.0790 - 0.0791 in)

(8)
Select the bearing by using selection table.
Crankshaft Main Bearing Selection Table
No. 1,2,4,5 journal
Crankshaft Main Bearing
Cylinder Block Crankshaft Journal Bore Mark
a (A)
b (B)
c (C)
Crank shaft main journal mark
I (1)
5 (Yellow)
4 : GREEN
3 : NONE
II (2)
4 : GREEN
3 : NONE
2 : BLOCK
III (3)
3 : NONE
2 : BLOCK
1 : BLUE

No. 3 journal
Crankshaft Main Bearing
Cylinder Block Crankshaft Journal Bore Mark
a (A)
b (B)
c (C)
Crank shaft main journal mark
I (1)
6 (RED)
5 (Yellow)
4 : GREEN
II (2)
5 (Yellow)
4 : GREEN
3 : NONE
III (3)
4 : GREEN
3 : NONE
2 : BLOCK

2.
Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Standard end play :
0.10 - 0.28 mm ( 0.0039 - 0.0110 in)

If the end play is greater than maximum, replace the center bearings as a set.
3.
Inspect the crankshaft main journals and pin journals.
Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal diameter :
47.942 - 47.960 mm (1.8874 - 1.8881 in)
Pin journal diameter :
38.954 - 38.972 mm (1.5336 - 1.5343 in)

Reassembly
  
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
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 5 upper bearings (A).

(2)
Install the thrust bearings.
Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

(3)
Install the crankshaft lower main bearing.
Align the bearing claw with the groove of the crankshaft lower bearing and crankshaft main bearing cap.
2.
Place the crankshaft (A) on the cylinder block.

3.
Install the main bearing caps.
  
Always use new main bearing cap bolts.
If any of the bearing cap bolts are broken or deformed, replace it.
(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) + 108 - 112°
  
Using the SST (09221-4A000), tighten the bolts which need to be tightened with the angular tightening method.

  
Do not reuse the main bearing cap bolts.
(3)
Check that the crankshaft turns smoothly.
4.
Check the crankshaft end play.
5.
Assemble 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")

    Piston and Connecting Rod

    Components and components location Components 1. Piston ring 2. Piston 3. Piston pin 4. Connecting rod 5...

    Cylinder Block

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

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