Hyundai i-30: Cylinder Block / Cylinder Block

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Mechanical System / 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 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")
14.
Remove the ladder frame (A).
Insert the blade of SST (09215-3C000) between the cylinder block and the ladder frame and cut out applied sealer. Then, remove the ladder frame.

  
Insert the SST between the cylinder block and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow.
After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the ladder frame, remove it from the cylinder block.
Do not turn over the SST abruptly without tapping as it may damage the SST.
Be careful not to damage the contacting surfaces of cylinder block and ladder frame.
15.
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
16.
Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
17.
Remove the water jacket seperator.
(Refer to Cylinder Block - "Water Jacket Seperator")
18.
Remove the piston cooling jet (A).

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 (0.002 in),
Less than 0.02 mm (0.0008 in) / 100 x 100 (3.937 x 3.937 in)

4.
Inspect the cylinder bore.
Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.
5.
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 :
71.60 - 71.63 mm (2.8188 - 2.8200 in)

6.
Check the cylinder bore size code on the cylinder block.

Discrimination of cylinder bore size
Grade
Size code
Cylinder Bore inner Diameter
a
A
71.60 - 71.61 mm
(2.8189 - 2.8193 in)
b
B
OVER 71.61 - TO 71.62 mm
(OVER 2.8193 - TO 2.8197 in)
c
C
OVER 71.62 - TO 71.63 mm
(OVER 2.8197 - TO 2.8201 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 piston cooling jet (A).
Tightening torque :
8.8 - 12.7 N.m (0.9 - 1.3 kgf.m, 6.5 - 9.4 lb-ft)

2.
Install the water jacket seperator.
(Refer to Cylinder Block - "Water Jacket Seperator")
3.
Install the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
4.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
5.
Install the ladder frame
(1)
Using a gasket scraper, remove all the old packing material.
  
Be careful not to damage the contact surfaces.
(2)
Install the O-ring (A) to cylinder block.

(3)
Before assembling the ladder frame, the liquid sealant MS721-40AA should be applied on ladder frame.
The part must be assembled with in 5 minutes after the sealant was applied.
Bead width : 2.5 - 3.5 mm (0.1 - 0.14 in.)

(4)
Install and uniformly tighten the ladder frame bolts, in several passes.
Tightening torque :
18.6 - 23.5 N.m, 1.9 - 2.4 kgf.m, 13.7 - 17.3 Ib-ft)

6.
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 Assembly - "Crankshaft")
Piston selection
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

    Crankshaft

    Components and components location Components 1. Thrust bearing 2. Upper main bearing 3. Crankshaft 4. Lower main bearing 5...

    Cooling System

    ..

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