Hyundai Elantra AD Quiz
Engine Mechanical System

Crankshaft Repair Procedures

In this manual: Engine Mechanical System
General Information — 9Engine Mechanical System — 84Engine Electrical System — 60Emission Control System — 24Engine Control System/Fuel System — 90Automatic Transmission — 92Drive Shaft and Axle — 20Suspension System — 31Steering — 20Restraints — 50Brake System — 63Body (Interior and Exterior) — 214Body Electrical System — 221Heating, Ventilation, and Air Conditioning — 71
31steps
~191min
5/5difficulty
1special tools
0102030405031.423N·mlb·ft
Tightening torque found on this page
Done 0 of 31

Disassembly
  • Use fender covers to avoid damaging painted surfaces.
  • To prevent damage to the cylinder head, wait until the engine coolant temperature drops below normal temperature (20 °C [68°F]) before removing it.
  • When handling the metal gasket, be careful not to bend the gasket or damage the gasket contact surface.
  • To avoid damage, carefully disconnect the wiring connectors by holding the connector body.
  • Label all wires and hoses to avoid incorrect connection.
  • 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. Automatic Transaxle (Refer to Automatic Transaxle System - "Automatic Transaxle")
  3. Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")
  4. Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")
  5. Install the engine on an engine stand for disassembly.
  6. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  7. Remove the water pump assembly. (Refer to Cooling System - "Water Pump")
  8. Remove the water inlet hose and thermostat assembly. (Refer to Cooling System - "Electric Thermostat (ECT)")
  9. Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
  10. Remove the A/C compressor. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
  11. Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  12. Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")
  13. Remove the oil filter. (Refer to Lubrication System - "Engine Oil")
  14. Remove the oil screen. (Refer to Lubrication System - "Oil Pan")
  15. Remove the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
  16. Check the crankshaft bearing oil clearance.
  17. Remove the lower oil pan (A).
    1. Remove the lower oil pan bolts.
    2. Remove the main bearing cap bolts.
  18. Check the crankshaft end play.
  19. Lift the crankshaft (A) out of the engine, taking care not to damage the journals.
    • Arrange the main bearings and thrust bearings in the correct order.

Inspection

  1. Check the crankshaft bearing oil clearance.
    1. To check the oil clearance between the main bearing and journal, remove the lower crankcase and lower bearings.
    2. Clean each main journal and bearing with a clean shop towel.
    3. Place one strip of Plastigage on each main journal.
    4. Install the lower crankcase and lower bearings, then tighten the main bolts. Tightening torque: Step 1: 27.5 ~ 31 N·m N·m; Step 2: 120 ~ 125°
      • Do not rotate the crankshaft.
    5. Remove the lower crankcase and lower bearings.
    6. Measure the width of the Plastigage at its widest point.

      Oil clearance: 0.016 ~ 0.034 mm (0.00063 ~ 0.00134 in.)

    7. If the Plastigage is too wide or too narrow, remove the upper and lower bearings, then install new bearings with the same color code. Recheck the oil clearance.
      • Do not grind, shim or scrape the bearings or caps to adjust the clearance.
    8. If the Plastigage indicates the clearance is still incorrect, try the next larger or smaller size bearing. Recheck the oil clearance.
      • If the proper clearance cannot be obtained using bearings of larger or smaller size, replace the crankshaft and start over.
      • If the markings are illegible due to dirt and dust buildup, do not scrape them off or use a wire brush. Clean them only with solvent or detergent.
      Crankshaft Bore Identification Mark
      Letters are stamped on the block as a size mark for each of the 5 main bearing bores. Use them, together with the numbers or the plate stamped on the crankshaft (main journal size marks), to select the correct bearings. Cylinder Block Specifications
      Class Mark Inner Diameter
      a A 59.000 ~ 59.006 mm
      (2.32283 ~ 2.32307 in.)
      D B 59.006 ~ 59.012 mm
      (2.32307 ~ 2.32330 in.)
      c C 59.012 ~ 59.018 mm
      (2.32330 ~ 2.32354 in.)

      Crankshaft Journal Identification Mark
      • Stamp in the order shown by the arrow direction from #1.
      Crankshaft Specifications
      Grade Mark Journal Outside Diameter
      I 1 54.954 ~ 54.960 mm
      (2.16354 ~ 2.16378 in.)
      II 2 54.948 ~ 54.954 mm
      (2.16330 ~ 2.16354 in.)
      III 3 54.942 ~ 54.948 mm
      (2.16307 ~ 2.16330 in.)

      Crankshaft Bearing Identification Mark
      Crankshaft Bearing Specifications
      Grade Mark Bearing Thickness
      A Blue 2.021 ~ 2.024 mm
      (0.07957 ~ 0.07968 in.)
      B Black 2.018 ~ 2.021 mm
      (0.07945 ~ 0.07957 in.)
      C None 2.015 ~ 2.018 mm
      (0.07933 ~ 0.07945 in.)
      D Green 2.012 ~ 2.015 mm
      (0.07921 ~ 0.07933 in.)
      E Yellow 2.009 ~ 2.012 mm
      (0.07909 ~ 0.07921 in.)
    9. Select the crankshaft bearing using the selection table. Crankshaft Bearing Selection Table
      Bearing Classification Assembly Crankshaft Bore Identification Mark
      A (A) B (B) C (C)
      Crankshaft Marking I (1) E (Yellow) D (Green) C (None)
      II (2) D (Green) C (None) B (Black)
      III (3) C (None) B (Black) Blue)
  2. Check the crankshaft end play. Using a dial indicator, measure the end play by moving the crankshaft back and forth with a screwdriver. If the end play exceeds the maximum, replace the center bearing.

    End play Standard: 0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)

  3. Inspect the main journals and crankpin journals. Using a micrometer, measure the diameter of each main journal and crankpin journal. Main journal diameter: 54.942 ~ 54.960 mm (2.16307 ~ 2.16378 in.) Crankpin journal diameter: 44.954 ~ 44.972 mm (1.76984 ~ 1.77055 in.)

Installation
  • Thoroughly clean all parts to be assembled.
  • Before installing parts, apply new engine oil to all sliding and rotating surfaces.
  1. Install the crankshaft main bearings.
    • The upper bearings have an oil groove and oil holes; the lower bearings do not.
    1. Align the bearing tab with the groove in the cylinder block, then insert the 5 upper bearings (A).
    2. Align the bearing tab with the groove in the lower crankcase (B), then insert the 5 lower bearings (A).
  2. Install the thrust bearings. Install the 2 thrust bearings (A) on both sides of the No. 3 cylinder block journal with the oil groove facing outward.
  3. Install the crankshaft (A) on the cylinder block.
  4. Apply liquid sealant to the upper surface of the lower crankcase.
    1. Using a gasket scraper, remove all old sealant from the gasket surfaces.
    2. The sealant application areas on the lower crankcase and cylinder block must be free of harmful foreign material, oil, dust and moisture. Spray cleaner on the surface and wipe with a clean cloth.
    3. Install a new rubber gasket (A) on the upper part of the lower crankcase.
    4. Apply liquid sealant to the lower part of the cylinder block. A continuous bead of sealant must be applied to prevent any oil leakage path. Bead width: 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.) Sealant: Threebond 1217H or equivalent
      • Assemble the lower crankcase within 5 minutes after applying the sealant.
      • Do not start the engine or perform a leak test within 30 minutes after assembling the lower crankcase.
      • Remove excess sealant from the sealant application surfaces of the next process before it hardens.
      • If sealant is applied to the upper surface of the lower crankcase, it must be in the same position as the cylinder block.
      • To prevent oil leakage, apply sealant to the internal threads of the bolt holes.
  5. Install the lower crankcase on the cylinder block.
  6. Install the main bearing cap bolts.
    Using SST (09221-4A000), install and tighten the 10 main bearing cap bolts in several passes in the specified sequence. Tightening torque: Step 1: 27.5 ~ 31 N·m N·m; Step 2: 120 ~ 125°
    • Do not reuse the bearing cap bolts.
    • Do not apply engine oil to the bolt threads to achieve the correct tightening torque.
    • The main bearing cap bolts are tightened in two steps.
    • If any bearing cap bolt is broken or deformed, replace it.
    • Assemble the main bearing cap bolts in the correct order.
  7. Install the lower crankcase bolts in several passes in the sequence shown in the illustration.

    Tightening Torque: 18.6 ~ 24 N·m

    Make sure the crankshaft rotates smoothly.
  8. Check the crankshaft end play.
  9. Assemble the remaining components in the reverse order of removal.
  • If replacing the crankshaft with a new one, select the correct connecting rod bearing according to the mark on the crankpin journal of the crankshaft.
  • Connecting Rod Bearing Selection (Refer to Cylinder Block - Piston and Connecting Rod)

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