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.

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.

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)

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.

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")

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)

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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