Hyundai Kona Quiz
Engine Mechanical System

Cylinder Block Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
27steps
~162min
4/5difficulty
Done 0 of 27

Disassembly

  1. Remove the engine and transaxle assembly from the vehicle. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
  2. Remove the dual clutch transmission. (Refer to DCT (Dual Clutch Transmission) - "DCT (Dual Clutch Transmission)").
  3. Remove the external damper flywheel. (Refer to Cylinder Block - "Flywheel with External Damper")
  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 intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
  7. Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  8. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  9. Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")
  10. Remove the oil pan and oil screen. (Refer to Lubrication System - "Oil Pan")
  11. Remove the oil cooler. (Refer to Lubrication System - "Engine Oil")
  12. Remove the oil pressure switch. (Refer to Lubrication System - Oil Pressure Switch)
  13. Remove the water inlet hose and thermostat. (See Cooling System - Thermostat)
  14. Remove the crankshaft position sensor. (See Engine Control System/Fuel System - Crankshaft Position Sensor (CKPS)).
  15. Remove the ladder frame. (See Cylinder Block Assembly - Piston and Connecting Rod)
  16. Inspect the connecting rod side clearance. (See Cylinder Block Assembly - Piston and Connecting Rod)
  17. Inspect the connecting rod bearing cap oil clearance. (See Cylinder Block Assembly - Piston and Connecting Rod)
  18. Remove the piston and connecting rod assembly. (See Cylinder Block Assembly - Piston and Connecting Rod)
  19. Inspect the main bearing oil clearance. (See Cylinder Block Assembly - Crankshaft)
  20. Inspect the crankshaft end play. (See Cylinder Block Assembly - Crankshaft)
  21. Remove the crankshaft. (See Cylinder Block Assembly - Crankshaft)
  22. Remove the knock sensor (KS). (Refer to Engine Control/Fuel System - Knock Sensor (KS)).

Inspection

  1. Using a gasket scraper, remove all gasket material from the upper surface of the cylinder block.
  2. 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 warpage. Cylinder block gasket surface flatness: Overall less than 0.05 mm (0.0020 in.); less than 0.02 mm (0.0008 in.) for a 100 mm x 100 mm (3.9370 x 3.9370 in.) area.
  4. Visually inspect the cylinder bore inner surface for scratches. Replace the cylinder block if any noticeable scratch is found. Replace the cylinder block if deep scratches are present.
  5. Using a cylinder bore gauge, measure the inner diameter of the cylinder bore in the axial and perpendicular-to-axial directions.

    Cylinder bore diameter: 77.00–77.03 mm (3.0315–3.0327 in.)

Installation

  1. Install in the reverse order of removal.

Test yourself

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