Hyundai i20 Quiz
Engine Mechanical System

Cylinder Block Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
39steps
~239min
5/5difficulty
1special tools
0102030405012.79N·mlb·ft
Tightening torque found on this page
Done 0 of 39

DISASSEMBLY

  1. Remove the engine assembly from the vehicle. (See Engine and Transaxle - Engine and Transaxle)
  2. Remove the transaxle assembly from the engine assembly. (See Manual Transaxle System - Manual Transaxle)
  3. Remove the flywheel. (See Cylinder Block Assembly - Flywheel)
  4. Remove the rear oil seal. (See Cylinder Block Assembly - Rear Oil Seal)
  5. Install the engine on an engine stand for disassembly.
  6. Remove the cylinder head cover. (Refer to Cylinder Head - "Cylinder Head Cover")
  7. Remove the thermostat housing. Refer to Cooling System - "Thermostat".
  8. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  9. Remove the intake manifold. (Refer to Exhaust and Intake System - "Intake Manifold")
  10. Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Turbocharger and Exhaust Manifold")
  11. Remove the cylinder head. (See Cylinder Head - Cylinder Head)
  12. Remove the oil pan and oil filter. (See Lubrication System - Oil Pan)
  13. Remove the ladder frame (A). Insert a stainless steel blade (09215-3C000) between the cylinder block and the ladder frame, and cut the sealant bead. Then remove the ladder frame.
  14. Inspect the connecting rod side clearance. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod".)
  15. Inspect the connecting rod bearing cap oil clearance. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod".)
  16. Remove the piston and connecting rod assembly. (Refer to Cylinder Block Assembly - Piston and Connecting Rod.)
  17. Inspect the main bearing oil clearance. (Refer to Cylinder Block Assembly - "Crankshaft".)
  18. Inspect the crankshaft end play. (Refer to Cylinder Block Assembly - "Crankshaft".)
  19. Remove the crankshaft. (Refer to Cylinder Block Assembly - "Crankshaft".)
  20. Remove the water jacket spacer. (Refer to Cylinder Block - "Water Jacket Spacer".)
  21. Remove the oil jet (A).

Inspection

  1. Remove the sealing material. Using a scraper, remove the sealant from the surface of the upper part of the cylinder block.
  2. Clean the cylinder block. Using a brush and solvent, thoroughly clean the cylinder block.
  3. Inspect the flatness of the cylinder block upper surface. Using a precision straightedge and feeler gauge, measure the distortion of the cylinder head gasket surface. Cylinder block gasket surface flatness 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. Make sure the cylinder is not scratched vertically. If deep scratches are found, replace the cylinder block.
  5. Inspect the cylinder bore diameter. Using a cylinder bore gauge, measure the bore diameter at the thrust and axial directions.

    Standard diameter: 71.00~71.03 mm (2.7952~2.7964 in)

  6. Check the cylinder bore size code on the cylinder block.
    Cylinder Block Specifications
    GRADE Mark Inside diameter
    B B 71.00~71.01 mm
    (2.79528~2.79567 in)
    B B 71.01~71.02 mm
    (2.79567~2.79606 in)
    AGAINST AGAINST 71.02~71.03 mm
    (2.79606~2.79646 in)
  7. Check the piston size code on the piston top surface.
    Piston Outer Diameter
    GRADE Mark Inside diameter
    B B 70.965~70.975 mm
    (2.79390~2.79429 in)
    B B 70.975~70.985 mm
    (2.79429~2.79469 in)
    AGAINST AGAINST 70.985~70.995 mm
    (2.79469~2.79508 in)
  8. Select a piston that matches the cylinder bore code.

    Clearance: 0.025 ~ 0.045 mm (0.00098 ~ 0.00177 in)

Installation

  1. Install the oil jet (A).

    Tightening torque: 8.8 - 12.7 N·m

  2. Install the water jacket spacer. (Refer to Cylinder Block - "Water Jacket Spacer".)
  3. Install the crankshaft. (Refer to Cylinder Block Assembly - "Crankshaft".)
  4. Inspect the crankshaft end play. (Refer to Cylinder Block Assembly - "Crankshaft".)
  5. Inspect the main bearing oil clearance. (Refer to Cylinder Block Assembly - "Crankshaft".)
  6. Install the piston and connecting rod assembly. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod".)
  7. Inspect the connecting rod bearing cap oil clearance. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod".)
  8. Inspect the connecting rod side clearance. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod".)
  9. Install the ladder frame.
    1. Using a scraper, remove the old sealant.
    2. Install the O-ring (A) on the cylinder block.
    3. Apply liquid sealant to the ladder frame mating surface before installing the ladder frame. Assemble the parts within 5 minutes after applying the sealant.

      Bead width: 2.5 ~ 3.5 mm (0.1 ~ 0.14 in)

    4. Install and tighten the frame bolts evenly, in several passes.

      Tightening torque: 19.6 - 24 N·m

  10. Install the remaining parts in the reverse order of removal.

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