Hyundai Santa Fe: Cylinder Block / Crankshaft. Repair procedures

Hyundai Santa Fe (TM) 2019-2024 Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft. 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.
(Refer to General Information - "Lift and Support Points")
  
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  
•
Mark all wiring and hoses to avoid misconnection.
•
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
•
Engine removal is required for this procedure.
1.
Remove piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
2.
Remove the lower crankcase.
(1)
Remove the lower crankcase mounting bolts (A).
(2)
Remove the crankshaft bearing cap bolts (A).
(3)
Remove the lower crankcase (A).
3.
Lift the crankshaft (A) out of the engine block, be careful not to damage journals.

4.
Remove the crankshaft position sensor wheel (A).
Inspection
1.
Check the crankshaft bearing oil clearance.
(1)
Clean each main journal and bearing half with a clean shop tower.
(2)
Place one strip of plastigage across each main journal.
(3)
Reinstall the bearing caps with lower bearings, and then tighten the bolts.
Tightening torque :
Crank lower case mounting bolts :
29.4 - 33.3 N.m (3.0 - 3.4 kgf.m, 21.6 - 24.5 Ib-ft)
Bearing cap mounting bolts :
27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 120 - 125°
Crank lower case mounting bolts :

Bearing cap mounting bolts :

  
•
Do not turn the crankshaft.
(4)
Remove the lower crankcase, and measure the widest part of the plasticgauge.
Bearing oil clearance :
#1,2,4,5 : 0.022~0.040mm (0.00086 - 0.00157 in.)
#3 : 0.028~0.046mm (0.00110 - 0.00181 in.)

(5)
If the plasticgauge measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark (select the color as shown in the next column). Recheck the oil clearance.
  
•
Do not file, shim, of scrape the bearings or the caps to adjust clearance.
(6)
If the plasticgauge 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.
  
•
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.
Cylinder Block Crankshaft Journal Bore Mark Location
Letters have been stamped on the side surface of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.

Class
Mark
Cylinder block crankshaft journal bore inner diameter
a
 A
 57.000 - 57.006 mm
(2.2441 - 2.2443 in.)
b
 B
 57.006 - 57.012 mm
(2.2443 - 2.2446 in.)
c
 C
 57.012 - 57.018 mm
(2.2446 - 2.2448 in.)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal
Class
Mark
Crankshaft main journal outer diameter
A
 1
 51.954 - 51.960 mm
(2.0454 - 2.0457 in.)
B
 2
 51.948 - 51.954 mm
(2.0452 - 2.0454 in.)
C
 3
 51.942 - 51.948 mm
(2.0450 - 2.0452 in.)

Crankshaft Bearing Identification Mark Location
[No. 2, No 3, No. 4 Journal Upper Bearing]

[No. 1, No 5 Journal Upper Bearing]

[Lower Bearing]

Discrimination Of Crankshaft Bearing
Class
Color
Bearing thickness
A
 LIGHT Blue
 2.518 - 2.521mm
(0.0991 - 0.0993in.)
B
 Black
 2.515 - 2.518mm
(0.0990 - 0.0991in.)
C
 WHITE
 2.512 - 2.515mm
(0.0989 - 0.0990in.)
D
 LIGT GREEN
 2.509 - 2.512mm
(0.0988 - 0.0989in.)
E
 PINK
 2.506 - 2.509 mm
(0.0987 - 0.0988 in.)
F
 YELLOW
 2.503 - 2.506 mm
(0.0985 - 0.0987 in.)

(7)
Select the bearing by using selection table.
Crankshaft Main Bearing Selection Table
Crank Shaft Journal & Cylinder Block Bore
Bearing Grade For Installing
Crank Shaft Class Mark
Cylinder Block Bore Mark
#1, 2, 4, 5 Journal
#3 Journal
I (1)
 a (A)
 E ( PINK)
 F (YELLOW)
b (B)
 D (LIGHT GREEN)
 E ( PINK)
c (C)
 C (WHITE)
 D (LIGHT GREEN)
I (2)
 a (A)
 D (LIGHT GREEN)
 E ( PINK)
b (B)
 C (WHITE)
 D (LIGHT GREEN)
c (C)
 B (BLACK)
 C (WHITE)
I (3)
 a (A)
 C (WHITE)
 D (LIGHT GREEN)
b (B)
 B (BLACK)
 C (WHITE)
c (C)
 A (LIGHT BLUE)
 B (BLACK)

2.
Check the crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
Crankshaft end play
0.100 - 0.280 mm (0.0039 - 1.0110 in.)

If the end play is greater than maximum, replace the thrust bearings as a set.
Thickness of thrust bearing :
2.41 - 2.45 mm (0.0948 - 0.9645 in.)
3.
Inspect the crankshaft main journals and pin journals.
Using a micrometer, measure the diameter of each main journal and pin journal.
Main journal diameter :
51.942 - 51.960 mm (2.0450 - 2.0457 in.)
Crank pin diameter :
47.954 - 47.972 mm (1.8879 - 1.8887 in.)

Reassembly
  
•
Thoroughly clean all parts to assembled.
•
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
•
Always use new gaskets, O-ring and oil seals.
1.
Install the crankshaft position sensor wheel (A).
Tightening torque :
26.5 - 27.5 N.m (2.7 - 2.8 kgf.m, 19.5 - 20.3 lb-ft)

  
•
Set the crankshaft position sensor wheel mark (Rear) so that it faces rear.
2.
Install the main bearing.
  
•
When installing the crankshaft upper bearings, the upper bearings should fit for each journal.
[No. 2, No 3, No. 4 Journal Upper Bearing]

[No. 1, No 5 Journal Upper Bearing]
(1)
Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A).
(2)
Align the bearing claw with the groove of the crank lower case, and push in the 5 lower bearings (A).
(3)
Apply a coat of engine oil after assembling the main bearings.
3.
Install the thrust bearings.
Install the 2 thrust bearings (A) on both sides of the No.4 journal of the cylinder block with the oil groove facing out.
4.
Install the crankshaft (A) on the cylinder block.

5.
Install the lower crankcase.
(1)
Make sure to remove hardened sealant, foreign matters, oil, dust, moisture on the sealing face of the liquid gasket of the lower crankcase.
Spray the cleaner on the sealing surface and wipe it off with a clean cloth.
(2)
Install the new O-ring (A) on the cylinder block.

(3)
Apply liquid sealant on lower crankcase. Then, assemble the part within 5 minutes of applying sealant.
(4)
Tighten the crankshaft bearing cap bolts several times according to the tightening sequence shown below.
Tightening torque
27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft) + 120 - 125°

  
•
Always use new bearing cap bolts.
(5)
Tighten the lower crankcase mounting bolts several times according to the tightening sequence shown below.
Tightening torque :
29.4 - 33.3 N.m (3.0 - 3.4 kgf.m, 21.6 - 24.5 Ib-ft)

(6)
Check that the crankshaft turns smoothly.
6.
Check the crankshaft end play.
7.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
8.
Assemble the other parts in the reverse order of disassembly.
  
•
In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft.
•
Connecting rod bearing selection
(Refer to Cylinder Block - "Piston and Connecting Rod")

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