Hyundai Creta: Cylinder Block Assembly / Piston and Connecting Rod

Components and components location

Components

1. Piston ring (#1)
2. Piston ring (#2)
3. Oil ring
4. Piston
5. Piston pin
6. Connecting rod
7. Connecting rod upper bearing
8. Connecting rod lower bearing
9. Connecting rod bearing cap

Repair procedures

Disassembly
  
Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.
1.
Remove the engine and transaxle assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2.
Remove the transaxle assembly from the engine assembly.
Manual Transaxle
(Refer to Manual Transaxle System - "Manual Transaxle")
Automatic Transaxle
(Refer to Automatic Transaxle System - "Automatic Transaxle")
3.
Remove the drive plate or flywheel.
Automatic Transaxle
(Refer to Cylinder Block Assembly - "Drive Plate")
Manual Transaxle
(Refer to Cylinder Block Assembly - "Flywheel")
4.
Remove the rear oil seal.
(Refer to Cylinder Block Assembly - "Rear Oil Seal")
5.
Install the engine assembly to engine stand for disassembly.
6.
Remove the intake manifold with the electronic throttle control (ETC) module.
(Refer to Intake And Exhaust System - "Intake Manifold")
7.
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
8.
Remove the timing chain.
(Refer to Timing System - "Timing Chain")
9.
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
10.
Remove the oil filter.
(Refer to Lubrication System - "Oil Filter")
11.
Remove the oil pan and the oil screen.
(Refer to Lubrication System - "Oil Pan")
12.
Remove the ladder frame (A).

13.
Check the connecting rod side clearance.
14.
Check the connecting rod bearing cap oil clearance.
15.
Remove the piston and connecting rod assemblies.
(1)
Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2)
Remove the connecting rod bearing caps (A).

  
Mark the connecting rod, and caps to be able to reassemble in the original position and direction.
(3)
Push the piston and connecting rod assembly with upper bearing through the top of the cylinder block.
  
Keep the connecting rod ands cap with their bearings assembled 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.
16.
Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
17.
Disassemble the piston rings.
(1)
Using a piston ring expender, remove the two compression rings (A).
(2)
Remove the oil ring (two side rails and one spacer) (B) by hand.
  
Do not apply excessive force to remove the oil ring from piston. It may cause to break the oil ring.
  
Arrange the piston rings in the correct order only.
18.
Disassemble the connecting rod (D) from the piston (C).
Using a hydraulic press, remove the piston pin (E) from piston.

Inspection
Connecting Rod
1.
Check the side clearance between piston and connecting rod.
Using feeler gauge, measure the side clearance while moving the connecting rod back and forth.
Side clearance
Standard : 0.1 ~ 0.25 mm (0.0039 ~ 0.0098 in)
Maximum : 0.35 mm (0.0138 in)
If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance after connecting rod replacement, replace the crankshaft.

2.
Check the connecting rod bearing oil clearance.
(1)
Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2)
Remove the 2 connecting rod cap bolts.
(3)
Remove the connecting rod cap and lower bearing.
(4)
Clean the crankshaft pin journal and bearing.
(5)
Place a plastigage across the crankshaft pin journal.
(6)
Reinstall the lower bearing and cap, and tighten the bolts.
Tightening torque :
27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 33.1 lb-ft) + 88°~92°
  
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 the connecting rod cap and lower bearing.
(8)
Measure the plastigage at its widest point.
Bearing oil clearance :
0.032 ~ 0.052 mm (0.0013 ~ 0.0020 in)

(9)
If the measurement from the plastigage is 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, of 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 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.
(11)
Select the bearing by using selection table.
Connecting Rod Bearing Selection Table
Connecting rod bearing
Connecting rod mark
0 (A, 0)
1 (B, 00)
2 (C, 000)
Crank shaft pin journal mark
1
E (Red)
D (Green)
C (None)
2
D (Green)
C (None)
B (Black)
3
C (None)
B (Black)
A (Blue)

Discrimination Of Connecting Rod
Class
Mark
Connecting rod big-end inner diameter
0
A, 0
45.000 ~ 45.006 mm
(1.7717 ~ 1.7719 in)
1
B, 00
45.006 ~ 45.012 mm
(1.7719 ~ 1.7721 in)
2
C, 000
45.012 ~ 45.018 mm
(1.7721 ~ 1.7724 in)

Discrimination Of Crankshaft Pin Journal
Class
Mark
Crankshaft pin journal outer diameter
I
1
41.966 ~ 41.972 mm
(1.6522 ~ 1.6524 in)
II
2
 41.960 ~ 41.966 mm
(1.6520 ~ 1.6522 in)
III
3
41.954 ~ 41.960 mm
(1.6517 ~ 1.6520 in)

[Type A]
Top surface stamp

[Type B]
Bottom surface stamp

Discrimination Of Connecting Rod Bearing
Class
Color
Connecting rod bearing thickness
A
Blue
1.514 ~ 1.517 mm
(0.0596 ~ 0.0597 in)
B
Black
1.511 ~ 1.514 mm
(0.0595 ~ 0.0596 in)
C
None
1.508 ~ 1.511 mm
(0.0594 ~ 0.0595 in)
D
Green
1.505 ~ 1.508 mm
(0.0593 ~ 0.0594 in)
E
Red or Yellow
1.502 ~ 1.505 mm
(0.0591 ~ 0.0593 in)

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 / 100 mm (3.94 in)
Allowable twist of connecting rod :
0.1 mm (0.0039 in ) or less / 100 mm (3.94 in)
Piston
1.
Clean the 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.
  
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.
Piston-to-cylinder clearance :
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)
(1)
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
Cylinder bore diameter :
77.00 ~ 77.03 mm (3.0315 ~ 3.0327 in)

(2)
Measure the piston outside diameter at 33.9 mm (1.5697 in) from top land of the piston.
Piston outside diameter :
76.97 ~ 77.00 mm (3.0303 ~ 3.0315 in)
3.
Select the piston matching with cylinder bore class.
Piston-to-cylinder clearance :
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)
(1)
Check the cylinder bore size mark on the side of the cylinder block.

Discrimination Of Cylinder Bore
Class
Mark
Cylinder bore inner diameter
a
A or 1
77.00 ~ 77.01 mm
(3.0315 ~ 3.0319 in)
b
B or 2
77.01 ~ 77.02 mm
(3.0319 ~ 3.0323 in)
c
C or 3
77.02 ~ 77.03 mm
(3.0323 ~ 3.0327 in)

(2)
Check the piston size mark on the piston top face.

Discrimination Of Piston Outer Diameter
Class
Mark
Piston outer diameter
A
A
76.97 ~ 76.98 mm
(3.0303 ~ 3.0307 in)
B
B
76.98 ~ 76.99 mm
(3.0307 ~ 3.0311 in)
C
C
76.99 ~ 77.00 mm
(3.0311 ~ 3.0315 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 ring groove.
Piston ring side clearance
[Standard]
No.1 ring : 0.04 ~ 0.08 mm (0.0015 ~ 0.0031 in)
No.2 ring : 0.04 ~ 0.08 mm (0.0015 ~ 0.0031 in)
Oil ring : 0.06 ~ 0.135 mm (0.0024 ~ 0.0053 in)
[Limit]
No.1 ring : 0.1 mm (0.0039 in)
No.2 ring : 0.1 mm ( 0.0039 in)
Oil ring : 0.2 mm ( 0.0079 in)

If the clearance is greater than maximum, replace the piston.
2.
Inspect the 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.
Piston ring end gap
[Standard]
No.1 ring : 0.14 ~ 0.28 mm (0.0079 ~ 0.0138 in)
No.2 ring : 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in)
Oil ring : 0.20 ~ 0.50 mm (0.0079 ~ 0.0276 in)
[Limit]
No.1 ring : 0.3 mm (0.0118 in)
No.2 ring : 0.5 mm (0.0197 in)
Oil ring : 0.8 mm (0.0315 in)

If the gap exceeds the specifications, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore is over the specifications, the cylinder block must be rebored.
Piston Pins
1.
Measure the outer diameter of piston pin
Piston pin diameter :
18.001 ~ 18.006 mm (0.7087 ~ 0.7089 in)

2.
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance :
0.010 ~ 0.020 mm (0.0004 ~ 0.0008 in)
3.
Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.
Piston pin-to-connecting rod interference :
-0.032 ~ -0.016 mm (-0.0013 ~ -0.0006 in)
Reassembly
  
Thoroughly clean all parts to assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1.
Assemble the piston and the connecting rod.
(1)
Apply a sufficient amount of engine oil to the outer surface of the piston pin and small end bore of the connecting rod.
(2)
Set the connecting rod and piston with the front marks upward on the support.
(3)
Press the piston pin into the small end bore of the connecting rod.
Pressing load : 500 ~ 1,500 kg (1,102 ~ 3,306 lb)

  
Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.
2.
Assemble the piston rings.
(1)
Install the oil ring (two side rails and one spacer) by hand.
(2)
Using a piston ring expander, install the 2 compression rings with the maker mark facing upward.
(3)
Position the piston rings so that the ring ends are as shown.
(The No.1 ring's end gap should be on the opposite side of the No.2 ring's end gap. The lower side rail's end gap should be on the opposite side of the upper side rail's end gap. The spacer's end gap should be between the lower and upper side rails.)
Example)

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

(2)
Apply a coat of engine oil after assembling the bearings.
4.
Insert the piston and connecting rod assemblies into the cylinder bores.
  
Before installing the piston, apply a sufficient amount of engine oil to the ring grooves and cylinder bores.
Insert the piston and connecting rod assembly with the front marks facing the front of the engine.

(1)
Press the piston rings with a ring compressor and check that the rings are securely in place. Then insert the piston into the cylinder bore, and tap it in using the wooden handle of a hammer.

(2)
Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
(3)
Install the rod caps with bearings, and tighten the bolts.
Tightening torque :
17.7 ~ 21.8 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°
Using the SST (09221-4A000), tighten the connecting rod cap bolts.

  
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.
5.
Check the side clearance between piston and connecting rod.
6.
Install the ladder frame.
(1)
Apply the liquid gasket on the ladder frame.
Bead width : 2.5 ~ 3.5 mm (0.0984 ~ 0.1378 in)

  
Apply the sealant, THREE-BOND 1217H or LOCTITE 5900H on the ladder frame rail portion and install it with in five minutes. If when sealant is applied to cylinder block bottom position, sealant position to be same with positon that is applied to ladder frame rail position.
Apply sealant along the inner line of the bolt holes.
(2)
Install the ladder frame (A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

7.
Assemble the other parts in the reverse order of disassembly.
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