Hyundai Genesis DH Quiz
Engine Mechanical System

Cylinder Block Repair Procedures

In this manual: Engine Mechanical System
General Information — 9Engine Mechanical System — 103Engine Electrical System — 54Emission Control System — 23Engine Control System/Fuel System — 127Automatic Transmission System (SBC) — 90All-Wheel Drive (AWD) System — 20Drive Shaft and Axle — 27Suspension System — 41Steering — 19Restraints — 56Brake System — 56Body (Interior and Exterior) — 211Body Electrical System — 279Heating, Ventilation, and Air Conditioning — 55
52steps
~312min
4/5difficulty
0102030405031.323N·mlb·ft
Tightening torque found on this page
Done 0 of 52

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 (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.
  • 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. Mount the engine on an 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 Systems — Intake Manifold)
  6. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  7. Remove the water temperature control unit. (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 cap (A) and gasket (B).
  11. Remove the water jacket spacer. (Refer to Cylinder Block - "Water Jacket Spacer")
  12. Remove the knock sensor (A).
  13. Remove the upper oil pan. (Refer to Lubrication System - "Oil Pan")
  14. Remove the baffle (A).
  15. Remove the rear oil seal retainer (A).
  16. Remove the oil drain plug (A) and gasket (B).
  17. Check the connecting rod side clearance. (Refer to Cylinder Block - Piston and Connecting Rod)
  18. Check the oil clearance of the connecting rod bearing cap. (Refer to Cylinder Block - Piston and Connecting Rod)
  19. Remove the piston and connecting rod assembly.
    1. Using a ridge reamer, remove all carbon from the upper part of the cylinder.
    2. Push the piston, connecting rod assembly, and upper bearing out 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.
  20. Remove the crankshaft main bearing cap and check the oil clearance. (Refer to Cylinder Block - Crankshaft)
  21. Check the crankshaft end play. (Refer to Cylinder Block - Crankshaft)
  22. Remove the crankshaft. (Refer to Cylinder Block - Crankshaft)
    Arrange the main bearings and thrust bearings in the correct order.
  23. Remove the oil jets (A).
  24. Disassemble the piston rings.
    1. Using a piston ring expander, remove the 2 compression rings (A).
    2. Remove the oil control ring and expander spring (B) by hand.
      Arrange the piston rings only in the correct order.
  25. Remove the snap rings from both ends of the piston pin, then push out the piston pin to separate the connecting rod.

Inspection

Cylinder block
  1. Remove the gasket material. Using a gasket scraper, remove all gasket material from the upper surface of the cylinder block.
  2. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
  3. Inspect the upper surface of the cylinder block for flatness. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head gasket for distortion. Cylinder block gasket surface flatness Standard: less than 0.05 mm (0.0020 in), Limit: less than 0.02 mm (0.0008 in) / 150 x 150
  4. Inspect the cylinder bore diameter. Visually check the cylinder for vertical scratches. If deep scratches are found, replace the cylinder block.
  5. Inspect the cylinder bore diameter. Using a cylinder bore gauge, measure the cylinder diameter in the axial and thrust directions.

    Standard diameter: 96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)
    Measurement direction: Axial direction, thrust direction
  6. Check the cylinder bore size code on the cylinder block.
    Grade Mark 3.8 L
    A A 96.00 to 96.01 mm
    (3.7795 to 3.7799 in)
    B B 96.01 to 96.02 mm
    (3.7799 to 3.7803 in)
    C C 96.02 to 96.03 mm
    (3.7803 to 3.7807 in)

    Maximum allowable size 96.28 mm (3.7905 in)

  7. Select oversize pistons according to the largest cylinder bore diameter.
    Identification Mark Size
    0,1 0.1 mm (0.004 in)
    0,25 0.25 mm (0.010 in)

    The piston size is stamped on the top of the piston.
  8. Measure the outside diameter of the piston to be used.
  9. Calculate the new bore size based on the measured outside diameter. New bore size = piston outside diameter + 0.03 to 0.05 mm (0.0012 to 0.0020 in) (piston-to-cylinder clearance) - 0.01 mm (0.0004 in) (honing allowance).
  10. Bore each of the cylinders to the calculated size.
    To prevent distortion caused by temperature rise during honing, bore the cylinders in firing order.
  11. Hone the cylinders to obtain the correct clearance (between cylinder and piston).
  12. Check the clearance between the piston and cylinder.

    Standard: 0.03 to 0.05 mm (0.0012 to 0.0020 in)
    When boring the cylinders, bore all cylinders to the same new bore size. Do not bore only one cylinder to the new bore size.
Cylinder Boring

Installation

  1. Install the oil jets (A).

    Torque 27.5 to 31 N·m

  2. Install the crankshaft. (Refer to Cylinder Block - Crankshaft)
  3. Install the crankshaft main bearing cap and check the oil clearance. (Refer to Cylinder Block - Crankshaft)
  4. Check the crankshaft end play. (Refer to Cylinder Block - Crankshaft)
  5. Install the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
  6. Check the connecting rod end play. (Refer to Cylinder Block - Piston and Connecting Rod)
  7. Install the plug bolt (A) and washer gasket (B).

    Torque: 83.4 to 103 N·m

  8. Install the rear oil seal retainer (A).

    Tightening torque: 9.8 ~ 11.8 N·m
    • Clean the sealing surfaces before assembling the two parts.
    • Remove harmful foreign material from the sealing surface before applying sealant.
    • Before assembling the rear oil seal retainer, apply liquid sealant THREE BOND 1217H to the rear oil seal retainer.
    • Complete the assembly within 5 minutes after applying the sealant.
    • Apply sealant to the internal threads of the bolt holes.
  9. Install the rear oil seal. (Refer to Cylinder Block - Rear Oil Seal)
  10. Install the baffle plate. When installing the baffle plate bolts, tighten the bolts in two or three steps in the sequence shown below.

    Tightening torque: 9.8 ~ 11.8 N·m

  11. Install the upper oil pan. (Refer to Lubrication System - Oil Pan)
  12. Install the No. 1 and No. 2 knock sensors. (Refer to Engine Control / Fuel System - Knock Sensor)
  13. Install the water jacket separator. (Refer to Cylinder Block - Water Jacket Separator)
  14. Install the oil cap (A) and gasket (B).

    Tightening torque: 9.8 ~ 11.8 N·m

  15. Assemble the remaining components in the reverse order of removal.
If replacing the cylinder block with a new one, select the correct crankshaft main bearing and piston according to the crankshaft journal bore mark and the cylinder bore mark stamped on the cylinder block.
  • Selection of Crankshaft Main Bearing (Refer to Cylinder Block - Crankshaft)
  • Selection of Piston (Refer to Cylinder Block - Piston and Connecting Rod)

Test yourself

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