Hyundai Palisade: Cylinder Block / Piston and Connecting Rod

Hyundai Palisade (LX2) 2020-2024 Service Manual / Engine Mechanical System / Cylinder Block / Piston and Connecting Rod

Repair procedures
Disassembly
Hyundai Palisade. 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")
Hyundai Palisade. Repair procedures   
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Hyundai Palisade. Repair procedures   
Mark all wiring and hoses to avoid misconnection.
Inspect the timing chain before removing the cylinder head.
Turn the crankshaft damper pulley so that the No.1 piston is at top dead center (TDC).
1.
Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine And Transaxle Assembly")
2.
Remove the transaxle assembly from the engine assembly.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
3.
Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "Drive Plate")
4.
Remove the rear oil seal case.
(Refer to Cylinder Block - "Rear Oil Seal")
5.
Install the engine assembly to engine stand for disassembly.
6.
Remove the surge tank.
(Refer to Intake and Exhaust System - "Surge Tank")
7.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
8.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
9.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
10.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
11.
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
12.
Remove the lower oil pan and upper oil pan.
(Refer to Lubrication System - "Oil Pan")
13.
Remove the oil pump.
(Refer to Lubrication System - "Oil Pump")
14.
Remove the oil filter body.
(Refer to Lubrication System - "Oil filter body")
15.
Remove the baffle plate (A).

Hyundai Palisade. Repair procedures

16.
Check the connecting rod end play.
17.
Check the connecting rod cap oil clearance.
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.
(2)
Remove the connecting rod bearing cap.
Hyundai Palisade. Repair procedures   
Mark the connecting rod, and caps to be able to reassemble in the original position and direction.
(3)
Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
Hyundai Palisade. Repair procedures   
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the correct order.
Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
19.
Disassemble the piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings (A).
(2)
Remove the oil ring and coil spring (B) by hand.
Hyundai Palisade. Repair procedures   
Arrange the piston rings in the correct order only.
20.
Disassemble the connecting rod from the piston.
(1)
Remove the snap ring (C) from the piston.
(2)
Using a press, remove the piston pin (D) from the piston.
(3)
Disassemble the piston (F) and connecting rod (E).

Hyundai Palisade. Repair procedures

Inspection
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.
Standard end play :
0.1 - 0.25 mm (0.004 - 0.010 in.)

Hyundai Palisade. Repair procedures

If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance, replace the crankshaft.
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.
(2)
Remove 2 connecting rod cap bolts.
(3)
Remove the connecting rod cap and bearing half.
(4)
Clean the crank pin and bearing.
(5)
Place plastigage across the crank pin.
(6)
Reinstall the bearing half and cap, and torque the bolts.
Tightening torque:
[27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)] + [68 - 72°]

Hyundai Palisade. Repair procedures

Hyundai Palisade. Repair procedures   
Do not turn the crankshaft.
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.
(7)
Remove 2 bolts, connecting rod cap and bearing half.
(8)
Measure the plastigage at its widest point.
Standard oil clearance:
0.042 - 0.060 mm (0.0017 - 0.0024 in.)

Hyundai Palisade. Repair procedures

(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.
Hyundai Palisade. Repair procedures   
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(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.
Hyundai Palisade. Repair procedures   
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
Hyundai Palisade. Repair procedures   
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.
Connecting Rod Mark Location

Hyundai Palisade. Repair procedures

Identification Of Connecting Rod
Class
Mark
Inside Diameter
0
a
58.000 - 58.006 mm
(2.2834 - 2.2837 in.)
1
b
58.006 - 58.012 mm
(2.2837 - 2.2839 in.)
2
c
58.012 - 58.018 mm
(2.2839 - 2.2842 in.)

Crankshaft Pin Mark Location
Identification Of Crankshaft

Hyundai Palisade. Repair procedures

Identification Of Crankshaft
Class
Mark
Outside Diameter Of Pin
I
1 or A
54.966 - 54.972 mm
(2.1640 - 2.1642 in.)
II
2 or B
54.960 - 54.966 mm
(2.1638 - 2.1640 in.)
III
3 or C
54.954 - 54.960 mm
(2.1635 - 2.1638 in.)

Place Of Identification Mark (Connecting Rod Bearing)

Hyundai Palisade. Repair procedures

Identification Of Connecting Rod Bearing
Class
Mark
Thickness Of Bearing
E
Blue
1.509 - 1.512 mm (0.0594 - 0.0595 in.)
D
Black
1.506 - 1.509 mm (0.0592 - 0.0594 in.)
C
Red
1.503 - 1.506 mm (0.0591 - 0.0592 in.)
B
Green
1.500 - 1.503 mm (0.0590 - 0.0591 in.)
A
Yellow
1.497 - 1.500 mm (0.0589 - 0.0590 in.)

(11)
Selection

Connecting Rod Identification Mark
0(a)
1(b)
2(c)
Crankshaft Identification Mark
1 or A
A
(Yellow)
B
(Green)
C
(Red)
2 or B
B
(Green)
C
(Red)
D
(Black)
3 or C
C
(Red)
D
(Black)
E
(Blue)

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.
(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.
(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.
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.)
Hyundai Palisade. Repair procedures   
When assembling the rod without a bearing, there should be no difference.
Piston
1.
Clean piston
(1)
Using a gasket scraper, remove the carbon from the piston top.
(2)
Using a groove cleaning tool, clean the piston ring grooves.
(3)
Using solvent and a brush, thoroughly clean the piston.
Hyundai Palisade. Repair procedures   
Do not use a wire brush.
2.
Check the piston - to - cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.
Clearance :
0.04 - 0.06 mm (0.0016 - 0.0024 in.)
(1)
Using a cylinder bore gauge, measure the cylinder bore diameter in the direction of the thrust and axial.
Standard diameter :
96.00 - 96.03 mm (3.7795 - 3.7807 in.)

Hyundai Palisade. Repair procedures

(2)
Measure the piston outside diameter at 14 mm (0.55118 in.) from bottom land of the piston.
Standard diameter :
95.95 - 95.98 mm (3.7776 - 3.7787 in.)

Hyundai Palisade. Repair procedures

3.
Select piston by the cylinder bore class.
Clearance :
0.04 - 0.06 mm (0.0016 - 0.0024 in.)
(1)
Check the cylinder bore size code on the cylinder block.

Hyundai Palisade. Repair procedures

Identification Of Cylinder Bore
Class
Size code
Cylinder bore inner diameter
A
A
96.00 - 96.01 mm (3.7795 - 3.7799 in.)
B
B
96.01 - 96.02 mm (3.7799 - 3.7803 in.)
C
C
96.02 - 96.03 mm (3.7803 - 3.7807 in.)

(2)
Check the piston size code (A) and the front mark (B) on the piston top face.

Hyundai Palisade. Repair procedures

Identification of Piston Outer Diameter
Class
Size code
Piston outer diameter
A
A
95.95 - 95.96 mm (3.7776 - 3.7779 in.)
B
B
95.96 - 95.97 mm (3.7779 - 3.7783 in.)
C
C
95.97 - 95.98 mm (3.7783 - 3.7787 in.)

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.
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.)

Hyundai Palisade. Repair procedures

If the clearance is greater than maximum, replace the piston.
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.
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.)

Hyundai Palisade. Repair procedures

Piston Pin
1.
Measure the diameter of the piston pin.
Piston pin diameter :
21.097 - 22.000 mm (0.8306 - 0.8661 in.)

Hyundai Palisade. Repair procedures

2.
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance :
0.004 - 0.013 mm (0.00015 - 0.00051 in.)
3.
Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference :
0.005 - 0.019 mm (0.00019 - 0.00074 in.)
Reassembly
Hyundai Palisade. Repair procedures   
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1.
Assemble the piston and the connecting rod.
(1)
Install the piston pin with two snap rings and check the snap ring assembly thoroughly.
(2)
The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.

Hyundai Palisade. Repair procedures

2.
Install the piston rings.
(1)
Install the coil spring and oil ring by hand.
(2)
Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3)
Position the piston rings so that the ring ends are as shown.

Hyundai Palisade. Repair procedures

3.
Install the connecting rod bearings.
(1)
Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2)
Install the bearings (A) in the connecting rod and connecting rod cap (B).

Hyundai Palisade. Repair procedures

Hyundai Palisade. Repair procedures   
When reassembling the connecting rods and caps, check the front marks and the number of cylinder.
4.
Attach the piston and connecting rod assemblies on the cylinder block.
Hyundai Palisade. Repair procedures   
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(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.
(2)
Stop when the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
(3)
Install the rod caps with bearings, and torque the bolts.
Tightening torque:
[27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)] + [68 - 72°]
Hyundai Palisade. Repair procedures   
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.

Hyundai Palisade. Repair procedures

5.
Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.
Tightening torque:
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

Hyundai Palisade. Repair procedures

6.
Assemble the remaining parts in the reverse order of disassembly.

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