Cylinder Block Hyundai Santa Fe III

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1. Remove the LH/RH cylinder head assembly and gasket. (Refer to " «CYLINDER HEAD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-head-assembly) ")
2. Remove the water jacket separator 1# (A) and 2# (B).

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1. Install the water jacket separator 1# (A) and 2# (B). NOTE: Insert the separator align with block inner side protrusion, and it must be located under the cylinder head installing surface.
2. Install the LH/RH cylinder head assembly and gasket. (Refer to " «CYLINDER HEAD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-head-assembly) ")

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1. Disconnect the battery "-" terminal.
2. Remove the automatic transaxle. (Refer to " «AUTOMATIC TRANSAXLE»(/hyundai/santa-fe/iii-2012-2016/remont/automatic-trans/#automatic-transaxle-system) ")
3. Remove the adapter plate (B) and the drive plate (A). Tightening torque: 71.6 ~ 75.5 N.m (7.3 ~ 7.7 kgf.m, 52.8 ~ 55.7 lb-ft)
4. Install in the reverse order of removal.

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1. Remove the drive plate. (Refer to Cylinder Block - " «DRIVE PLATE»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
2. Remove the rear oil seal (A).

Scheme 230

1. Using SST (09231-3C200, 09231-H1100), install the rear oil seal. NOTE: Always use new oil seal.
2. Install the drive plate. (Refer to Cylinder Block - " «DRIVE PLATE»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")

Scheme 231

Disassembly

Note. Mark all wiring and hoses to avoid misconnection. Inspect the timing chain before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center (TDC).

Scheme 232

1. Remove the engine assembly from the vehicle. (Refer to " «ENGINE AND TRANSMISSION ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#engine-and-transmission-assembly) ")
2. Remove the drive plate and adapter plate. (Refer to Cylinder Block - " «DRIVE PLATE»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
3. Attach the engine to engine stand for disassembly.
4. Remove the exhaust manifold. (Refer to " «EXHAUST MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
5. Remove the intake manifold. (Refer to " «INTAKE MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
6. Remove the timing chain. (Refer to " «TIMING CHAIN»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#timing-system) ")
7. Remove the water temperature control assembly. (Refer to " «WATER TEMPERATURE CONTROL ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/cooling-system-mechanical/#engine-cooling-system) ")
8. Remove the cylinder head. (Refer to " «CYLINDER HEAD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-head-assembly) ")
9. Remove the oil pump. (Refer to " «OIL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
10. Remove the oil filter body. (Refer to " «OIL FILTER BODY»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
11. Remove the upper oil pan. (Refer to " «OIL PAN»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
12. Remove the baffle plate (A).
13. Check the connecting rod end play.
14. Check the connecting rod cap oil clearance.
15. Detach the piston and connecting rod assemblies from the cylinder block. Using a ridge reamer, remove all the carbon from the top of the cylinder. Remove the connecting rod bearing cap. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
16. Remove the piston rings. Using a piston ring expander, remove the 2 compression rings. Remove the oil ring and coil spring by hand. NOTE: Arrange the piston rings in the correct order only.
17. Disconnect the connecting rod from piston. Remove the snap ring at both ends of piston pin. And push the piston pin to separate and connecting rod.

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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.) 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. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove 2 connecting rod cap bolts. Remove the connecting rod cap and bearing half. Clean the crank pin and bearing. Place plastigage across the crank pin. 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°] NOTE: Do not turn the crankshaft. Remove 2 bolts, connecting rod cap and bearing half. Measure the plastigage at its widest point. Standard oil clearance: 0.040 ~ 0.062 mm (0.0016 ~ 0.0024 in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: 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.

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IDENTIFICATION OF CONNECTING ROD

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DISCRIMINATION OF CRANKSHAFT

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IDENTIFICATION OF CONNECTING ROD BEARING

1. (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)

1. 3. Check the connecting rod. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction. 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. Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it. Allowable bend 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.) NOTE: When assembling the rod without a bearing, there should be no difference.

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1. Clean piston Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: 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 : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.) Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction Standard diameter: 92.00 ~ 92.03 mm (3.6220 ~ 3.6232 in.) Measure the piston outside diameter at 14 mm (0.55118 in.) from bottom land of the piston. Standard diameter: 91.96 ~ 91.99 mm (3.6204 ~ 3.6216 in.)
3. Select the piston matching with cylinder bore class. Clearance : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.) Check the cylinder bore size code on the cylinder block. DISCRIMINATION OF CYLINDER BORE Class Size code Cylinder bore inner diameter A A 92.00 ~ 92.01 mm (3.6220 ~ 3.6224 in.) B B 92.01 ~ 92.02 mm (3.6224 ~ 3.6228 in.) C C 92.02 ~ 92.03 mm (3.6228 ~ 3.6232 in.) Check the piston size code (A) and the front mark (B) on the piston top face. DISCRIMINATION OF PISTON OUTER DIAMETER Class Size code Piston outer diameter A A 91.96 ~ 91.97 mm (3.6204 ~ 3.6208 in.) B B 91.97 ~ 91.98 mm (3.6208 ~ 3.6212 in.) C C 91.98 ~ 91.99 mm (3.6212 ~ 3.6216 in.)

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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.) 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 ~ 0.32 mm (0.0067 ~ 0.0126 in.) No. 2: 0.37 ~ 0.52 mm (0.0145 ~ 0.0204 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.)

Scheme 245

1. Measure the diameter of the piston pin. Piston pin diameter: 21.097 ~ 22.00 mm (0.8305 ~ 0.8661 in.)
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

Note. 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.

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1. Assemble the piston and the connecting rod. Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly. The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings. Install the oil ring spacer and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Position the piston rings so that the ring ends are as shown in the illustration.
3. Install the connecting rod bearings. Align the bearing claw with the groove of the connecting rod or connecting rod cap. Install the bearings (A) in the connecting rod and connecting rod cap (B). CAUTION: When reassembling the connecting rods and the caps, ensure the front marks on then and the number of cylinder.
4. Attach the piston and connecting rod assemblies from the cylinder block. NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores. Install the ring compressor, 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. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place. 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°] NOTE: Always use new connecting rod bearing cap bolts. Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore. NOTE: Use SST (09221-4A000), install connecting rod bearing cap bolts.
5. Install the baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in the illustration. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
6. Install all other parts in reverse order of removal.

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Note. Mark all wiring and hoses to avoid misconnection. Inspect the timing chain before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center (TDC).

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1. Remove the engine assembly from the vehicle. (Refer to " «ENGINE AND TRANSMISSION ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#engine-and-transmission-assembly) ")
2. Remove the drive plate and adapter plate. (Refer to Cylinder Block - " «DRIVE PLATE»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
3. Attach the engine to engine stand for disassembly.
4. Remove the exhaust manifold. (Refer to " «EXHAUST MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
5. Remove the intake manifold. (Refer to " «INTAKE MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
6. Remove the timing chain. (Refer to " «TIMING CHAIN»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#timing-system) ")
7. Remove the water temperature control assembly. (Refer to " «WATER TEMPERATURE CONTROL ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/cooling-system-mechanical/#engine-cooling-system) ")
8. Remove the cylinder head. (Refer to " «CYLINDER HEAD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-head-assembly) ")
9. Remove the oil pump. (Refer to " «OIL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
10. Remove the oil filter body. (Refer to " «OIL FILTER BODY»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
11. Remove the upper oil pan. (Refer to " «OIL PAN»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
12. Remove the baffle plate (A).
13. Remove the rear oil seal case (A).
14. Check the connecting rod end play. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
15. Check the connecting rod cap oil clearance. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
16. Remove the piston and connecting rod assemblies. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
17. Remove the crankshaft main bearing cap and check oil clearance.
18. Check the crankshaft end play.
19. Remove the crankshaft. Lift the crankshaft (A) out of engine, being careful not to damage journals. NOTE: Arrange the main bearings and thrust bearings in the correct order.

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1. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves. Clean each main journal and bearing half with a clean shop tower. Place one strip of plastigage across each main journal. Reinstall the bearings and caps, then torque the bolts. Tightening torque No. 1~8: 49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90° No. 9~16: 19.6 N.m (2.0 kgf.m, 14.5 lb-ft) + 120° No. 17~24: 29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft) NOTE: Do not turn the crankshaft. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance: 0.022 ~ 0.040 mm (0.0009 ~ 0.0016 in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: 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. Crankshaft bore mark location Letters have been stamped on the block as a mark for the size of each of the 4 main journal bores. Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings. DISCRIMINATION OF CYLINDER BLOCK Class Mark Inside Diameter a A 73.500 ~ 73.506 mm (2.8937 ~ 2.8939 in.) b B 73.506 ~ 73.512 mm (2.8939 ~ 2.8942 in.) c C 73.512 ~ 73.518 mm (2.8942 ~ 2.8944 in.)

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DISCRIMINATION OF CRANKSHAFT

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DISCRIMINATION OF CRANKSHAFT BEARING

CRANKSHAFT BORE IDENTIFICATION MARK - SELECTION

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1. 2. Check crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard end play: 0.10 ~ 0.28 mm (0.0039 ~ 0.0110 in.) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness: 2.41 ~ 2.45 mm (0.0949 ~ 0.0964 in.)
2. 3. Inspect main journals and crank pins Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 68.942 ~ 68.960 mm (2.7142 ~ 2.7149 in.) Crank pin diameter: 54.954 ~ 54.972 mm (2.1635 ~ 2.1642 in.)

Note. 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.

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1. Install the main bearings. NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A). Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
2. Install the thrust bearings. Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
3. Place the crankshaft (A) on the cylinder block.
4. Place the main bearing caps on cylinder block.
5. Install the main bearing cap bolts. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown in the illustration. Tightening torque Main bearing cap bolt No. 1~8: 49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90° No. 9~16: 19.6 N.m (2.0 kgf.m, 14.5 lb-ft) + 120° No. 17~24: 29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft) NOTE: Always use new main bearing cap bolts. If any of the bearing cap bolts are broken or deformed, replace it. Use the SST (09221-4A000), install main bearing cap bolts. Check that the crankshaft turns smoothly.
6. Check crankshaft end play.
7. Install the piston and connecting rod assemblies. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
8. Install the rear oil seal case (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) NOTE: Clean the sealing face before assembling two parts. Remove harmful foreign materials on the sealing face before applying sealant Before assembling rear oil seal case, the liquid sealant THREE BOND 1217H should be applied to the rear oil seal case. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
9. Install the rear oil seal. (Refer to " «REAR OIL SEAL»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
10. Install the baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in the illustration. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. Install all other parts in reverse order of removal. Information 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»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")

Note. Mark all wiring and hoses to avoid misconnection. Inspect the timing chain before removing the cylinder head. Turn the crankshaft pulley so that the No. 1 piston is at top dead center (TDC).

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1. Remove the engine assembly from the vehicle. (Refer to " «ENGINE AND TRANSMISSION ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#engine-and-transmission-assembly) ")
2. Remove the drive plate and adapter plate. (Refer to Cylinder Block - " «DRIVE PLATE»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
3. Attach the engine to engine stand for disassembly.
4. Remove the exhaust manifold. (Refer to " «EXHAUST MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
5. Remove the intake manifold. (Refer to " «INTAKE MANIFOLD»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) ")
6. Remove the timing chain. (Refer to " «TIMING CHAIN»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#timing-system) ")
7. Remove the water temperature control assembly. (Refer to " «WATER TEMPERATURE CONTROL ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/cooling-system-mechanical/#engine-cooling-system) ")
8. Remove the cylinder head. (Refer to " «CYLINDER HEAD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-head-assembly) ")
9. Remove the oil pump. (Refer to " «OIL PUMP»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
10. Remove the oil filter body. (Refer to " «OIL FILTER BODY»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
11. Remove the oil cover (A) and gasket (B).
12. Remove the water jacket separator. (Refer to Cylinder Block - " «WATER JACKET SEPARATOR»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
13. Remove the knock sensor (A).
14. Remove the upper oil pan. (Refer to " «OIL PAN»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
15. Remove the baffle plate (A).
16. Remove the rear oil seal case (A).
17. Remove the oil drain cover (A) and gasket (B).
18. Check the connecting rod end play. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
19. Check the connecting rod cap oil clearance. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
20. Remove the piston and connecting rod assemblies. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
21. Remove the crankshaft main bearing cap and check oil clearance. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
22. Check the crankshaft end play. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
23. Remove the crankshaft. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
24. Remove the oil jets (A).

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1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of the cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Standard: Less than 0.05 mm (0.0020 in.), Less than 0.02 mm (0.0008 in.)/150 x 150
4. Inspect cylinder bore diameter. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect cylinder bore diameter. Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions. Standard diameter: 92.00 ~ 92.03 mm (3.6220 ~ 3.6232 in.)
6. Check the cylinder bore size code on the cylinder block. Class Size code Cylinder bore inner diameter A A 92.00 ~ 92.01 mm (3.6220 ~ 3.6224 in.) B B 92.01 ~ 92.02 mm (3.6224 ~ 3.6228 in.) C C 92.02 ~ 92.03 mm (3.6228 ~ 3.6232 in.)

Cylinder boring

1. Oversize pistons should be selected according to the largest bore cylinder. Identification Mark Size 0.1 0.1 mm (0.004 in) 0.25 0.25 mm (0.010 in) NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D (Outer Diameter), calculate the new bore size. New bore size = piston O.D + 0.03 to 0.05 mm (0.0012 to 0.0020 in) (clearance between piston and cylinder) - 0.01 mm (0.0004 in) (honing margin.)
4. Bore each of the cylinders to the calculated size. CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder. Standard : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in) NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.

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1. Install the oil jets (A). Tightening torque 27.5 ~ 31.3 N.m (2.8 ~ 3.2kgf.m, 20.2 ~ 23.1lb-ft)
2. Install the crankshaft. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
3. Install the crankshaft main bearing cap and check oil clearance. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
4. Check the crankshaft end play. (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
5. Install the piston and connecting rod assemblies. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
6. Check the connecting rod end play. (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
7. Install the oil drain cover (A) with a new gasket (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
8. Install the rear oil seal case (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) NOTE: Clean the sealing face before assembling two parts. Remove harmful foreign materials on the sealing face before applying sealant Before assembling rear oil seal case, the liquid sealant THREE BOND 1217H should be applied to the rear oil seal case. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
9. Install the rear oil seal. (Refer to " «REAR OIL SEAL»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
10. Install the baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in the illustration. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. Install the upper oil pan. (Refer to " «OIL PAN»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) ")
12. Install the knock sensor (A). Tightening torque: 15.7 ~ 23.5 N.m (1.6 ~ 2.4 kgf.m, 11.6 ~ 17.3 lb-ft)
13. Install the water jacket separator. (Refer to Cylinder Block - " «WATER JACKET SEPARATOR»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")
14. Remove the oil cover (A) and gasket (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
15. Install all other parts in reverse order of removal. Information In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block. Crankshaft main bearing selection (Refer to Cylinder Block - " «CRANKSHAFT»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ") Piston selection (Refer to Cylinder Block - " «PISTON AND CONNECTING ROD»(/hyundai/santa-fe/iii-2012-2016/remont/mechanical/#cylinder-block) ")

See also:
• CYLINDER HEAD
• AUTOMATIC TRANSAXLE
• ENGINE AND TRANSMISSION ASSEMBLY
• EXHAUST MANIFOLD
• TIMING CHAIN
• WATER TEMPERATURE CONTROL ASSEMBLY
• OIL PUMP
• DRIVE PLATE