Connecting Rod
| 1. |
Check the connecting rod side clearance.
Using a feeler gauge, measure the end play while moving the connecting
rod back and forth.
| A. |
If out-of-tolerance, install a new connecting rod.
|
| B. |
If still out-of-tolerance, replace the crankshaft.
|
Side clearance
Standard: 0.10~ 0.25 mm (0.0039 ~ 0.0098 in.)
|
|
| 2. |
Check the connecting road bearing oil clearance.
| (1) |
Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
|
| (2) |
Remove 2 connecting rod cap bolts.
|
| (3) |
Remove the connecting rod cap and lower bearing.
|
| (4) |
Clean the crank pin and bearing.
|
| (5) |
Place a plastigage across the crankshaft pin journal.
|
| (6) |
Reinstall the lower bearing and cap, and torque the bolts.
Tightening torque
1st step:
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9
lb-ft)
2nd step: 88 ~ 92°
|
|
Do not turn the crankshaft.
|
|
| (7) |
Remove the connecting rod cap and lower bearing.
|
| (8) |
Measure the width of the plastigage at its widest point.
Oil clearance:
0.028 ~ 0.046 mm (0.00110 ~ 0.00181 in.)
|
|
| (9) |
If the measurement from the plastigage is too wide or
too narrow, remove the upper and lower bearing and then install
new bearings with the same color mark. Recheck the oil clearance.
|
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
|
|
| (10) |
If the plastigage shows the clearance is still incorrect,
try the next larger or smaller bearing. Recheck the oil clearance.
|
If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearings, replace
the crankshaft and repeat the check procedure.
|
|
If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them with
a wire brush or scraper. Clean them only with solvent
or detergent.
|
Connecting Rod Identification Mark
Connecting Rod Specifications
Class
|
Mark
|
Inside Diameter
|
0
|
A
|
48.000 ~ 48.006 mm
(1.88976 ~ 1.89000 in.)
|
1
|
B
|
48.006 ~ 48.012 mm
(1.89000 ~ 1.89023 in.)
|
2
|
C
|
48.012 ~ 48.018 mm
(1.89023 ~ 1.89047 in.)
|
Crankshaft Pin Identification Mark
|
Conform to read stamping order as shown arrow
direction from #1.
|
Crankshaft Specifications
Class
|
Mark
|
Outside Diameter Of Pin
|
I
|
1
|
44.966 ~ 44.972 mm
(1.77031 ~ 1.77055 in.)
|
II
|
2
|
44.960 ~ 44.966 mm
(1.77008 ~ 1.77031 in.)
|
III
|
3
|
44.954 ~ 44.960 mm
(1.76984 ~ 1.77008 in.)
|
Connecting Rod Bearing Identification Mark
Connecting Rod Bearing Specifications
Class
|
Mark
|
Thickness Of Bearing
|
A
|
Blue
|
1.509 ~ 1.512 mm
(0.05941 ~ 0.05953 in.)
|
B
|
Black
|
1.506 ~ 1.509 mm
(0.05929 ~ 0.05941 in.)
|
C
|
None
|
1.503 ~ 1.506 mm
(0.05917 ~ 0.05929 in.)
|
D
|
Green
|
1.500 ~ 1.503 mm
(0.05906 ~ 0.05917 in.)
|
E
|
Yellow
|
1.497 ~ 1.500 mm
(0.05894 ~ 0.05906 in.)
|
|
| (11) |
Select a connecting rod bearing using selection chart.
Selection Chart For Connecting Rod Bearings
Assembling Classification Of Bearing
|
Connecting Rod Identification Mark
|
0 (A)
|
1 (B)
|
2(C)
|
Crankshaft Identification Mark
|
I (1)
|
E
(Yellow)
|
D (Green)
|
C (None)
|
II (2)
|
D (Green)
|
C (None)
|
B (Black)
|
III (3)
|
C (None)
|
B (Black)
|
A (Blue)
|
|
|
| 3. |
Check the connecting rods.
| (1) |
When reinstalling, make sure that cylinder numbers put
on the connecting rod and cap at disassembly match. When a new
connecting rod is installed, make sure that the notches for
holding the bearing in place are on the same side.
|
| (2) |
Replace the connecting rod if it is damaged on the thrust
faces at either end. Also if step wear or a severely rough surface
of the inside diameter of the small end is apparent, the rod
must be replaced as well.
|
| (3) |
Using a connecting rod aligning tool, check the rod for
bend and twist. If the measured value is close to the repair
limit, correct the rod by a press. Any connecting rod that has
been severely bent or distorted should be replaced.
Allowable bend of connecting rod:
0.05 mm (0.0020 in.) or less for 100 mm (3.94
in.)
Allowable twist of connecting rod:
0.10 mm (0.0039 in.) or less for 100 mm (3.94
in.)
|
|
When the connecting rods are installed without
bearings, there should be no difference on side surface.
|
|
|
Crankshaft
| 1. |
Check the crankshaft bearing oil clearance.
| (1) |
To check main bearing-to-journal oil clearance, 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 across each main journal.
|
| (4) |
Reinstall the lower crankcase and lower bearings, and
then tighten the main bolts.
Tightening torque
1st step:
27.5 ~ 31.4 N.m (2.8~3.2 kgf.m, 20.3 ~ 23.1 lb-ft)
2nd step: 120 ~ 125°
|
|
Do not turn 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 measures too wide or too narrow, remove
the upper and lower bearing and then install a new bearings
with the same color mark. Recheck the oil clearance.
|
Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
|
|
| (8) |
If the plastigage shows the clearance is still incorrect,
try the next larger or smaller bearing. Recheck the oil clearance.
|
If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearings, replace
the crankshaft and start over.
|
|
If the marks are indecipherable because of an
accumulation of dirt and dust, do not scrub them with
a wire brush or scraper. Clean them only with solvent
or detergent.
|
Crankshaft Bore Identification Mark
Letters have been stamped on the block as a mark for the
size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank
(marks for main journal size), to choose the correct bearings.
Cylinder Block Specifications
Calss
|
Mark
|
Inside Diameter
|
a
|
A
|
59.000 ~ 59.006 mm
(2.32283 ~ 2.32307 in.)
|
b
|
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
|
Conform to read stamping order as shown arrow
direction from #1.
|
Crankshaft Specifications
Class
|
Mark
|
Outside Diameter Of Journal
|
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
Class
|
Mark
|
Thickness Of Bearing
|
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 ~ 0.7933 in.)
|
E
|
Yellow
|
2.009 ~ 2.012 mm
(0.07909 ~ 0.07921 in.)
|
|
| (9) |
Select a crankshaft bearing using the selection chart.
Selection Chart For Crankshaft Bearings
Assembling Classification Of Bearing
|
Crankshaft Bore Identification Mark
|
a (A)
|
b (B)
|
c (C)
|
Crankshaft Identification Mark
|
I (1)
|
E (Yellow)
|
D (Green)
|
C (None)
|
II (2)
|
D (Green)
|
C (None)
|
B (Black)
|
III (3)
|
C (None)
|
B (Black)
|
A (Blue)
|
|
|
| 2. |
Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
If the end play is greater than maximum, replace the center bearing.
End play
Standard: 0.07 ~ 0.25 mm (0.0028 ~ 0.0098 in.)
|
|
| 3. |
Inspect main journals and crank pins.
Using a micrometer, measure the diameter of each main journal
and crank pin.
Main journal diameter:
54.942 ~ 54.960 mm (2.16307 ~ 2.16378 in.)
Crank pin diameter:
44.954 ~ 44.972 mm (1.76984 ~ 1.77055 in.)
|
|
Cylinder Block
| 1. |
Remove gasket material.
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
|
| 2. |
Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder
block.
|
| 3. |
Inspect top surface of cylinder block for flatness.
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head gasket for warpage.
Flatness of cylinder block gasket surface
Standard:
Less than 0.05 mm (0.0020 in.) for total area
Less than 0.02 mm (0.0008 in.) for a section of 100 mm
(3.9370 in.) X 100 mm (3.9370 in.)
|
|
| 4. |
Inspect the cylinder bore
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
|
| 5. |
Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter
at position in the thrust and axial direction.
Cylinder bore diameter:
81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)
|
|
Measure position points (from the top of the cylinder
block):
30 mm (1.1811 in.) / 60 mm (2.3622 in.) / 90 mm (3.5433
in.)
|
|
| 6. |
Check the cylinder bore size code on the cylinder block side surface.
Cylinder Bore Inner Diameter
Size Code
|
Cylinder Bore Inner Diameter
|
A
|
81.00 ~ 81.01 mm (3.1890 ~ 3.1894 in.)
|
B
|
81.01 ~ 81.02 mm (3.1894 ~ 3.1898 in.)
|
C
|
81.02 ~ 81.03 mm (3.1898 ~ 3.1902 in.)
|
|
| 7. |
Check the piston size mark on the piston top face.
Piston Outer Diameter
Size Code
|
Piston Outer Diameter
|
A
|
80.97 ~ 80.98 mm (3.1878 ~ 3.1882 in.)
|
B
|
80.98 ~ 80.99 mm (3.1882 ~ 3.1886 in.)
|
C
|
80.99 ~ 81.00 mm (3.1886 ~ 3.1890 in.)
|
|
| 8. |
Select the piston related to cylinder bore class.
Piston-to-cylinder clearance:
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
|
|
Piston And Piston Rings
| 1. |
Clean piston.
| (1) |
Using a gasket scraper, remove the carbon from the piston
top.
|
| (2) |
Using a groove cleaning tool or broken ring, clean the
piston ring grooves.
|
| (3) |
Using solvent and a brush, thoroughly clean the piston.
|
|
| 2. |
The standard measurement of the piston outside diameter is taken
35 mm (1.3780 in.) from top land of the piston.
Piston outside diameter:
80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)
|
|
| 3. |
Calculate the difference between the cylinder bore inner diameter
and the piston outer diameter.
Piston-to-cylinder clearance:
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
|
|
| 4. |
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston
ring and the wall of ring groove.
If the clearance is greater than maximum, replace the piston.
Piston ring side clearance
[Standard]
No.1 ring:
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
No.2 ring:
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring:
0.060 ~ 0.145 mm (0.00236 ~ 0.00571 in.)
|
|
| 5. |
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into
the cylinder bore. Position the ring at right angles to the cylinder
wall by gently pressing it down with a piston. Measure the gap with
a feeler gauge.
If the gap exceeds the service limit, replace the piston rings.
If the gap is too large, recheck the cylinder bore inner diameter. If
the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
[Standard]
No.1 ring: 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
No.2 ring: 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
Oil ring : 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in.)
|
|
Piston Pins
| 1. |
Measure the diameter of the piston pin.
Piston pin diameter:
19.996 ~ 20.000 mm (0.78724 ~ 0.78740 in.)
|
|
| 2. |
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance:
0.004 ~ 0.013 mm (0.00016 ~ 0.00051 in.)
|
|
| 3. |
Check the clearance between the piston pin outer diameter and
the connecting rod small end inner diameter.
Piston pin-to-connecting rod clearance:
0.010 ~ 0.025 mm (0.00039 ~ 0.00098 in.)
|
|
Engine removal is required for this procedure.
•
Use fender covers to avoid damaging painted surfaces.
...
•
Thoroughly clean all parts to be assembled.
•
Before instal ...
Hyundai Elantra MD/UD: Inspection
