Cylinder block (Hyundai Sonata EF)

Cylinder block (2.0L/2.4L engines).

1 - oil pressure switch sensor, 2 - cylinder block, 3 - engine support bracket.

Cylinder block (2.7L engine).

1 - cylinder block, 2 - main bearing cap, 3 - connecting bracket of main bearing caps.

Examination

1. Check the cylinder block for chips, corrosion, scale deposits and rust. Also check for cracks and other damage. Replace the cylinder block if significant defects are found.

2. Using a straightedge and a flat feeler gauge, check the warpage (non-flatness) of the cylinder block mating surface under the gasket. Before checking, make sure that the cylinder block surface is clean of any old gasket residue and foreign particles. If the non-flatness exceeds the maximum permissible value, grind the surface to the permissible value or replace the cylinder block.

Note: the total thickness of metal removed from the cylinder head and cylinder block during mechanical processing should not exceed 0.2 mm in total.

2.0L/2.4L Engines:

Nominal value: 0.05 mm
Maximum permissible value: no more than 0.10 mm

2.7L Engine:

Nominal value: 0.03 mm
Maximum permissible value: no more than 0.05 mm

Engines 2.0 l / 2.4 l.

Engine 2.7 l.

3. Measure the cylinder diameter using a bore gauge in three zones along the height in the directions "A" and "B". Take measurements in the places shown in the figure:
(1) - TDC of the piston (stopping point of compression ring No.1); (2) - middle of piston stroke; (3) - BDC of the piston.

Nominal cylinder diameter:

2.0L Engine: 85.00-85.03mm
2.4L Engine: 86.50-86.53mm
2.7L Engine: 86.70-86.73mm

Engines 2.0 l / 2.4 l.

Engine 2.7 l.

4. If either the out-of-roundness (ovality) or taper of the cylinder is greater than the maximum permissible value, or there are scratches or signs of seizure (scuffing) on the cylinder mirror, the cylinders of the block should be bored to the appropriate repair size and honed. After repairing the cylinder block, install pistons and piston rings of the appropriate repair size.

Maximum permissible non-roundness and taper of the cylinder (no more than):

2.0L/2.4L engines: 0.01mm
2.7L Engine: 0.02mm

5. Check the mirror of each cylinder for damage and cracks.

Repair

Cylinder boring

Caution: Ream all four cylinders to the same oversize. Do not ream only one cylinder to the oversize.

1. If there is a build-up (ridge wear) around the perimeter of the cylinder in its upper part, remove it using a special tool.

2. Based on the largest diameter of the cylinder of the engine being repaired, obtained as a result of measurements, determine the repair size number of the pistons.

Identification marks of piston repair sizes:

2.0L/2.4L Engines:

Repair size: 0.50 mm
Label: 0.50

2.7L Engine:

Repair size: 0.25 mm; 0.50 mm
Label: 0.25; 0,50

Nominal piston diameter:

2.0L Engine: 84.97-85.00mm
2.4L Engine: 86.47-86.50mm
2.7L Engine: 86.68-86.70mm

Please note: the piston repair size number identification mark is stamped on the piston crown.

3. Measure the outside diameter of the piston to be used at the location shown in the figure.

Clearance between piston and cylinder:

2.0/2.4L engines: 0.02-0.04 mm
2.7L Engine: 0.01-0.03mm

Note: Standard piston diameter measurements are taken at a distance of 12 mm from the skirt edge in a plane perpendicular to the piston pin axis.

4. When repairing (boring and honing) cylinders to the repair size, calculate the bore diameter of the cylinder so that the repair results in the nominal clearance between the piston and the cylinder. Check that all pistons being installed are of the same repair size.

5. Based on the measured value of the piston outside diameter, calculate the cylinder bore diameter.

Cylinder bore diameter = Piston outside diameter + (clearance between piston and cylinder) - (honing allowance).

Honing allowance:

2.0L/2.4L engines: 0.02mm
2.7L Engine: 0.01mm

6. Bore all cylinders to the calculated diameter.

Attention:

(2.0L/2.4L engines) To prevent thermal deformations during boring, bore the cylinders in the following sequence: No.2, No.4, No.1, No.3.

(2.7L Engine) To prevent thermal deformations during boring, bore the cylinders in the order of engine operation (1-2-3-4-5-6).

7. Hone the cylinders to the final finished dimension (piston outside diameter + piston to cylinder clearance).

Attention:

(2.0L / 2.4L engines) To prevent thermal distortion during honing, process the cylinders in the following sequence: No.2, No.4, No.1 and No.3.

(2.7L Engine) To prevent thermal deformations during honing, process the cylinders in the order of engine operation (1-2-3-4-5-6).

8. Check the clearance between the piston and the cylinder (established limit for new parts).

Nominal value: