Hyundai Tucson Quiz
Engine Mechanical System

Cylinder Block Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 51Engine Electrical System — 26Emission Control System — 23Engine/Fuel Control System — 44Clutch System — 12MANUAL TRANSMISSION SYSTEM — 12AUTOMATIC TRANSMISSION SYSTEM — 42Four-Wheel Drive (4WD) System — 14Drive Shaft and Axle — 22Suspension System — 30Steering System — 16Restraint — 21Braking System — 47Body Work (Interior and Exterior) — 145Body Electrical System — 162Heating, Ventilation and Air Conditioning — 39
24steps
~144min
4/5difficulty
0102030405023.517N·mlb·ft
Tightening torque found on this page
Done 0 of 24

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. Automatic Transaxle (Refer to Automatic Transaxle System - "Automatic Transaxle")
  3. Automatic Transaxle: 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. (Refer to Cooling System - "Water Pump".)
  8. Remove the water inlet pipe and thermostat. Refer to Cooling System - "Thermostat".
  9. Remove the intake manifold. (Refer to Exhaust and Intake System - "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. (See Cylinder Head - Cylinder Head)
  13. Remove the oil filter. (Refer to Lubrication System - "Engine Oil")
  14. Remove the oil filter. (Refer to Lubrication System - "Oil Pan")
  15. Remove the piston and connecting rod assembly. (Refer to Cylinder Block - Piston and Connecting Rod)
  16. Remove the crankshaft. (Refer to Cylinder Block - Crankshaft)
  17. Remove the knock sensor (A).

Inspection

  1. Remove the packing material. Using a scraper, remove the sealant from the upper surface of the cylinder block.
  2. Clean the cylinder block. Using a 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 cylinder head gasket surface for distortion. Cylinder block gasket surface flatness STANDARD: Overall maximum 0.05 mm (0.0020 in.) Maximum 0.02 mm (0.0008 in.) per 100 mm (3.9370 in.) x 100 mm (3.9370 in.) area
  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.

    Cylinder bore diameter: 81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)

REMEDY

  1. Install the knock sensor (A).

    Tightening Torque: 18.6 ~ 24 N·m

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

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