Hyundai Palisade: Cylinder Block / Piston and Connecting Rod
Repair procedures
| • |
Be careful not to damage the parts located under the vehicle
(floor under cover, fuel filter, fuel tank and canister) when
raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
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| • |
Use fender covers to avoid damaging painted surfaces.
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| • |
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
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| • |
Mark all wiring and hoses to avoid misconnection.
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| • |
Inspect the timing chain before removing the cylinder head.
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| • |
Turn the crankshaft damper pulley so that the No.1 piston is
at top dead center (TDC).
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| 1. |
Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine And Transaxle Assembly")
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| 2. |
Remove the transaxle assembly from the engine assembly.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
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| 3. |
Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
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| 4. |
Remove the rear oil seal case.
(Refer to Cylinder Block - "Rear Oil Seal")
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| 5. |
Install the engine assembly to engine stand for disassembly.
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| 6. |
Remove the surge tank.
(Refer to Intake and Exhaust System - "Surge Tank")
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| 7. |
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
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| 8. |
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
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| 9. |
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
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| 10. |
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
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| 11. |
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
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| 12. |
Remove the lower oil pan and upper oil pan.
(Refer to Lubrication System - "Oil Pan")
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| 13. |
Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
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| 14. |
Remove the oil filter body.
(Refer to Lubrication System - "Oil filter body")
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| 15. |
Remove the baffle plate (A).
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| 16. |
Check the connecting rod end play.
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| 17. |
Check the connecting rod cap oil clearance.
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| 18. |
Detach the piston and connecting rod assemblies from the cylinder block.
| (1) |
Using a ridge reamer, remove all the carbon from the top of
the cylinder.
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| (2) |
Remove the connecting rod bearing cap.
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• |
Mark the connecting rod, and caps to be able
to reassemble in the original position and direction.
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| (3) |
Push the piston, connecting rod assembly and upper bearing through
the top of the cylinder block.
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Keep the bearings, connecting rod and cap together.
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Arrange the piston and connecting rod assemblies
in the correct order.
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Mark the piston and connecting rod assemblies
to be able to reassemble in the original position.
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| 19. |
Disassemble the piston rings.
| (1) |
Using a piston ring expander, remove the 2 compression rings
(A).
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| (2) |
Remove the oil ring and coil spring (B) by hand.
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• |
Arrange the piston rings in the correct order
only.
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| 20. |
Disassemble the connecting rod from the piston.
| (1) |
Remove the snap ring (C) from the piston.
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| (2) |
Using a press, remove the piston pin (D) from the piston.
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| (3) |
Disassemble the piston (F) and connecting rod (E).
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Connecting Rod And Crankshaft
| 1. |
Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting
rod back and forth.
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Standard end play :
0.1 - 0.25 mm (0.004 - 0.010 in.)
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| • |
If out-of-tolerance, install a new connecting rod.
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| • |
If still out-of-tolerance, replace the crankshaft.
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| 2. |
Check the connecting rod bearing oil clearance.
| (1) |
Check that the match marks on the connecting rod and cap are
aligned to ensure correct reassembly.
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| (2) |
Remove 2 connecting rod cap bolts.
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| (3) |
Remove the connecting rod cap and bearing half.
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| (4) |
Clean the crank pin and bearing.
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| (5) |
Place plastigage across the crank pin.
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| (6) |
Reinstall the bearing half and cap, and torque the bolts.
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Tightening torque:
[27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)]
+ [68 - 72°]
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• |
Do not turn the crankshaft.
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• |
Always use new connecting rod cap bolts. Connecting
rod cap bolts are toque-to-yield bolts designed
to be permanently elongated beyond the state
of elasticity when torqued, so if the bolts
are removed and reused, it may cause the bolts
to break or fail to maintain clamping force.
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| (7) |
Remove 2 bolts, connecting rod cap and bearing half.
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| (8) |
Measure the plastigage at its widest point.
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Standard oil clearance:
0.042 - 0.060 mm (0.0017 - 0.0024 in.)
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| (9) |
If the plastigage shows that the clearance is still incorrect,
try the next larger or smaller bearing (the color listed above
or below that one), and check clearance again.
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• |
Do not file, shim, or scrape the bearings or
the caps to adjust clearance.
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| (10) |
If the plastigage shows the clearance is stillincorrect, try
the next larger or smaller bearing(the color listed above or
below that one), andcheck clearance again.
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• |
If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
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• |
If the marks are indecipherable because of an
accumulation of dirt and dust, clean with solvent
or detergent instead of scrubbing with a wire
brush or scraper.
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Connecting Rod Mark Location
Identification Of Connecting Rod
Class
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Mark
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Inside Diameter
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0
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a
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58.000 - 58.006 mm
(2.2834 - 2.2837 in.)
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1
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b
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58.006 - 58.012 mm
(2.2837 - 2.2839 in.)
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2
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c
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58.012 - 58.018 mm
(2.2839 - 2.2842 in.)
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Crankshaft Pin Mark Location
Identification Of Crankshaft
Identification Of Crankshaft
Class
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Mark
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Outside Diameter Of Pin
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I
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1 or A
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54.966 - 54.972 mm
(2.1640 - 2.1642 in.)
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II
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2 or B
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54.960 - 54.966 mm
(2.1638 - 2.1640 in.)
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III
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3 or C
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54.954 - 54.960 mm
(2.1635 - 2.1638 in.)
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Place Of Identification Mark (Connecting Rod Bearing)
Identification Of Connecting Rod Bearing
Class
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Mark
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Thickness Of Bearing
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E
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Blue
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1.509 - 1.512 mm (0.0594 - 0.0595 in.)
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D
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Black
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1.506 - 1.509 mm (0.0592 - 0.0594 in.)
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C
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Red
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1.503 - 1.506 mm (0.0591 - 0.0592 in.)
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B
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Green
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1.500 - 1.503 mm (0.0590 - 0.0591 in.)
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A
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Yellow
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1.497 - 1.500 mm (0.0589 - 0.0590 in.)
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| (11) |
Selection
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Connecting Rod Identification Mark
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0(a)
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1(b)
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2(c)
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Crankshaft Identification Mark
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1 or A
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A
(Yellow)
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B
(Green)
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C
(Red)
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2 or B
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B
(Green)
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C
(Red)
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D
(Black)
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3 or C
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C
(Red)
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D
(Black)
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E
(Blue)
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| 3. |
Check the connecting rod.
| (1) |
When reinstalling, check the cylinder numbers on the connecting
rods and the caps. When installing a new connecting rod, the
bearing fixing notches on the connecting rods and caps should
face the same direction.
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| (2) |
If one or both edge of the connecting rod thrust surface is
damaged, replace the rod. If the inner surface of the rod is
damaged or rough, also replace it.
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| (3) |
Using the connecting rod aligner, measure the bending and torsion
of the rod. If the measurement is close to the specification,
adjust the rod with a press. If the rod is bent or twisted excessively,
replace it.
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Allowable bending of connecting rod
0.05 mm/100 mm (0.0020 in./3.9370 in.)
Allowable twist of connecting rod
0.1 mm/100 mm (0.0039 in./3.9370 in.)
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• |
When assembling the rod without a bearing, there
should be no difference.
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Piston
| 1. |
Clean piston
| (1) |
Using a gasket scraper, remove the carbon from the piston top.
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| (2) |
Using a groove cleaning tool, clean the piston ring grooves.
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| (3) |
Using solvent and a brush, thoroughly clean the piston.
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• |
Do not use a wire brush.
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| 2. |
Check the piston - to - cylinder clearance by calculating the difference
between the cylinder bore inner diameter and the piston outer diameter.
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Clearance :
0.04 - 0.06 mm (0.0016 - 0.0024 in.)
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| (1) |
Using a cylinder bore gauge, measure the cylinder bore diameter
in the direction of the thrust and axial.
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Standard diameter :
96.00 - 96.03 mm (3.7795 - 3.7807 in.)
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| (2) |
Measure the piston outside diameter at 14 mm (0.55118 in.) from
bottom land of the piston.
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Standard diameter :
95.95 - 95.98 mm (3.7776 - 3.7787 in.)
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| 3. |
Select piston by the cylinder bore class.
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Clearance :
0.04 - 0.06 mm (0.0016 - 0.0024 in.)
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| (1) |
Check the cylinder bore size code on the cylinder block.
Identification Of Cylinder Bore
Class
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Size code
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Cylinder bore inner diameter
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A
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A
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96.00 - 96.01 mm (3.7795 - 3.7799 in.)
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B
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B
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96.01 - 96.02 mm (3.7799 - 3.7803 in.)
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C
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C
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96.02 - 96.03 mm (3.7803 - 3.7807 in.)
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| (2) |
Check the piston size code (A) and the front mark (B) on the
piston top face.
Identification of Piston Outer Diameter
Class
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Size code
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Piston outer diameter
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A
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A
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95.95 - 95.96 mm (3.7776 - 3.7779 in.)
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B
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B
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95.96 - 95.97 mm (3.7779 - 3.7783 in.)
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C
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C
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95.97 - 95.98 mm (3.7783 - 3.7787 in.)
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Piston Rings
| 1. |
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring
and the wall of the ring groove.
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Piston ring side clearance
Standard
No.1 : 0.04 - 0.08 mm (0.0015 - 0.0031 in.)
No.2 : 0.04 - 0.08 mm (0.0015 - 0.0031 in.)
Oil ring : 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Limit
No.1 : 0.1 mm (0.004 in.)
No.2 : 0.1 mm (0.004 in.)
Oil ring : 0.2 mm (0.008 in.)
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If the clearance is greater than maximum, replace the piston.
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| 2. |
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 ring. If the
gap is too large, recheck the cylinder bore diameter against the wear
limits. If the bore is over the service limit, the cylinder block must
be replaced.
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Piston ring end gap
Standard
No.1 : 0.17 - 0.24 mm (0.0067 - 0.0094 in.)
No.2 : 0.32 - 0.47 mm (0.0126 - 0.0185 in.)
Oil ring :
0.20 - 0.40 mm (0.0078 - 0.0157 in.)
Limit
No.1 : 0.6 mm (0.0236 in.)
No.2 : 0.7 mm (0.0275 in.)
Oil ring : 0.8 mm (0.0315 in.)
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Piston Pin
| 1. |
Measure the diameter of the piston pin.
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Piston pin diameter :
21.097 - 22.000 mm (0.8306 - 0.8661 in.)
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| 2. |
Measure the piston pin-to-piston clearance.
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Piston pin-to-piston clearance :
0.004 - 0.013 mm (0.00015 - 0.00051 in.)
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| 3. |
Check the difference between the piston pin diameter and the connecting
rod small end diameter.
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Piston pin-to-connecting rod interference :
0.005 - 0.019 mm (0.00019 - 0.00074 in.)
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| • |
Thoroughly clean all parts to be assembled.
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| • |
Before installing the parts, apply fresh engine oil to all sliding
and rotating surfaces.
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| • |
Replace all gaskets, O-rings and oil seals with new parts.
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| 1. |
Assemble the piston and the connecting rod.
| (1) |
Install the piston pin with two snap rings and check the snap
ring assembly thoroughly.
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| (2) |
The piston front mark (A) and the connecting rod front mark
(B) must face the timing belt side of the engine.
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| 2. |
Install the piston rings.
| (1) |
Install the coil spring and oil ring by hand.
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| (2) |
Using a piston ring expander, install the 2 compression rings
with the code mark facing upward.
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| (3) |
Position the piston rings so that the ring ends are as shown.
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| 3. |
Install the connecting rod bearings.
| (1) |
Align the bearing claw with the groove of the connecting rod
or connecting rod cap.
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| (2) |
Install the bearings (A) in the connecting rod and connecting
rod cap (B).
|
• |
When reassembling the connecting rods and caps,
check the front marks and the number of cylinder.
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| 4. |
Attach the piston and connecting rod assemblies on the cylinder block.
| •
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Before installing the pistons, apply a coat of engine
oil to the ring grooves and cylinder bores.
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| (1) |
Install the ring compressor, and check that the bearing is securely
in place. Then, position the piston in the cylinder, and tap
it in using the wooden handle of a hammer.
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| (2) |
Stop when the ring compressor pops free, and check the connecting
rod-to-check journal alignment before pushing the piston into
place.
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| (3) |
Install the rod caps with bearings, and torque the bolts.
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Tightening torque:
[27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)]
+ [68 - 72°]
|
|
• |
Always use new connecting rod cap bolts. Connecting
rod cap bolts are torque-to-yield bolts designed
to be permanently elongated beyond the state
of elasticity when torqued, so if the bolts
are removed and reused, it may cause the bolts
to break or fail to maintain clamping force.
|
|
• |
Maintain downward force on the ring compressor
to prevent the rings from expanding before entering
the cylinder bore.
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| 5. |
Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes,
in the sequence shown.
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Tightening torque:
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)
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| 6. |
Assemble the remaining parts in the reverse order of disassembly.
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Repair procedures
Replacement
•
Be careful not to damage the parts located under the vehicle
(floor under cover, fuel filter, fuel tank and canister) when
raising the vehicle using the lift...
Repair procedures
Disassembly
•
Be careful not to damage the parts located under the vehicle
(floor under cover, fuel filter, fuel tank and canister) when
raising the vehicle using the lift...
Other information:
Cooling / Ventilation
1. Select the Face Level mode.
2. Set the air intake control to fresh
mode.
3. Set the temperature control to the
desired position.
4. Set the fan speed control to the
desired speed.
Heating
1. Select the Floor Level mode.
2...
Replacement
•
Wear gloves to protect hands from injury.
•
Take care not to scratch the body surface...
Categories
The front seat can be adjusted by
using the levers located on the outside
of the seat cushion. Before driving,
adjust the seat to the proper
position so that you can easily control
the steering wheel, foot pedals
and controls on the instrument
panel.
read more
Rear Oil Seal
Crankshaft