Contents: Removal ⇓ Examination ⇓
Removal
1. Remove the timing belt, cylinder head, front cover, flywheel, pistons with connecting rods and crankshaft.
2. Using special tool 09260–32000, remove the oil pressure sensor.
Examination
1. Remove any gaskets, sealant, dirt, oil, grease, and other foreign materials from the engine block. Visually inspect the cylinder block for rust, corrosion, cracks, and other defects.
2. Clean the mating surfaces of the cylinder head and cylinder block from gasket residues. Use a metal ruler and feeler gauge in six directions to check the flatness of the mating surface of the cylinder block.
Original version of the article on the website: HyundaiBook
- Flatness deviation: 0.03 mm
- Maximum permissible deviation from flatness: 0.15 mm
3. Measure the cylinder diameters in diametrically opposite directions, in three planes along the height of the cylinders. If the cylinder diameters exceed the permissible values, are oval or conical, or the cylinder surface is damaged or has wear, the cylinder block must be bored and new pistons and piston rings of repair size must be installed.
Nominal cylinder diameter, mm:
- 1.6L engine: 76.50–76.52
- 1.5L engine: 5.50–75.53
Ovality and taper of cylinders: no more than 0.01 mm
4. If there is a step at the top of the cylinder, cut it off with a special tool.
5. Pistons of four larger sizes are supplied as spare parts: 0.25, 0.5, 0.75 and 1.00 mm.
6. When reboring cylinders to the nearest oversize, maintain the clearance between the piston and cylinder and ensure that the pistons are the same oversize. Measure the outside diameter of each piston at 47 mm from the piston crown.
Clearance between piston and cylinder, mm:
- 1.6L engines: 0.025–0.045
- 1.5l engines: 0.02–0.04