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2012 ENGINE
CYLINDER BLOCK
COMPONENTS AND COMPONENTS LOCATION
Components
REPAIR PROCEDURES
Disassembly
1. Remove the engine assembly from the vehicle. (Refer to ENGINE AND TRANSAXLE ASSEMBLY in
this group)
2. Remove the transaxle assembly from the engine assembly. (Refer to Automatic Transaxle or Manual
Transaxle System )
3. Manual transaxle: Remove the flywheel (A).
Automatic transaxle: Remove the drive plate (A) and the adapter plate (B).
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: Arrange the main bearings and thrust bearings in the correct order.
24. 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.
25. Remove piston rings.
1. Using a piston ring expander, remove the 2 compression rings.
2. Remove 2 side rails and the oil ring by hand.
26. Remove the snap rings and then disassemble the connecting rod from the piston.
Inspection
Connecting Rod
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Side clearance
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Tightening torque
1st step:
Oil clearance:
9. If the measurement from the plastigage is too wide or too narrow, remove the upper and lower
bearing and then install new bearings with the same color mark. Recheck the oil clearance.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
clearance.
10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
CRANKSHAFT SPECIFICATIONS
Class Mark Outside Diameter Of Pin
44.966 ~ 44.972 mm
I 1
(1.77031 ~ 1.77055 in.)
44.960 ~ 44.966 mm
II 2
(1.77008 ~ 1.77031 in.)
44.954 ~ 44.960 mm
III 3
(1.76984 ~ 1.77008 in.)
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: When the connecting rods are installed without bearings, there
should be no difference on side surface.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Crankshaft
Tightening torque
1st step:
Oil clearance:
7. If the plastigage measures 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.
CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust
clearance.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
8. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.
Recheck the oil clearance.
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the
correct bearings.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
CRANKSHAFT SPECIFICATIONS
Class Mark Outside Diameter Of Journal
54.954 ~ 54.960 mm
I 1
(2.16354 ~ 2.16378 in.)
54.948 ~ 54.954 mm
II 2
(2.16330 ~ 2.16354 in.)
54.942 ~ 54.948 mm
III 3
(2.16307 ~ 2.16330 in.)
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.
If the end play is greater than maximum, replace the center bearing.
End play
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Using a micrometer, measure the diameter of each main journal and crank pin.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Cylinder Block
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylinder block.
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket
for warpage.
Standard:
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) X 100 mm (3.9370 in.)
Fig. 20: Measuring Surface Contacting Cylinder Head Gasket For Warpage
Courtesy of HYUNDAI MOTOR CO.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial
direction.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: Measure position points (from the top of the cylinder block):
30 mm (1.1811 in.)/60 mm (2.3622 in.)/90 mm (3.5433 in.)
6. Check the cylinder bore size code on the cylinder block side surface.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Piston-to-cylinder clearance:
1. Clean 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.
2. The standard measurement of the piston outside diameter is taken 35 mm (1.3780 in.) from top land of the
piston.
3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Piston-to-cylinder clearance:
Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.
[Standard]
No. 1 ring:
No. 2 ring:
Oil ring:
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 rings. If the gap is too large, recheck the cylinder
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
bore inner diameter. If the bore is over the service limit, the cylinder block must be replaced.
[Standard]
Piston Pins
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
3. Check the clearance between the piston pin outer diameter and the connecting rod small end inner
diameter.
Reassembly
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: Apply a sufficient amount of engine oil to outer surface of the piston, inner
surface of piston pin hole and small end bore of the connecting rod before
inserting the piston pin.
CAUTION: l Be careful not to damage and scratch the small end bore, piston
pin hole and piston pin when inserting the piston pin.
l Set the snap ring firmly so that the snap ring can contact with
the whole groove of the piston pin hole.
Example)
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
CAUTION: Check to ensure that the oil ring can be turned smoothly.
NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
1. Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A).
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
2. Align the bearing claw with the groove of the lower crankcase (B), and push in the 5 lower
bearings (A).
Install the 2 thrust bearings (A) on both sides of the No. 3 journal of the cylinder block with the oil
groove facing out.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
4. Apply liquid sealant on the bottom of the cylinder block. Continuous bead of sealant should be
applied to prevent any path from oil leakage.
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Using SST (09221-4A000), install and tighten the 10 main bearing cap bolts, in several passes, in the
sequence as shown.
Tightening torque
1st step:
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: l The main bearing cap bolts are tightened in 2 progressive steps.
l If any of the bearing cap bolts is broken or deformed, replace it.
l Be sure to assemble the main bearing cap bolts in correct order.
10. Install the lower crankcase bolts, in several passes, in sequence as shown.
Tightening torque:
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
NOTE: l Before installing the piston, apply a coat of engine oil to the ring
grooves and cylinder bores.
l Install the piston and connecting rod assembly with the front marks
facing the front of the engine.
1. Install the ring compressor, check that the rings are securely in place, and then position the piston
in the cylinder, 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. Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.
Tightening torque
1st step:
NOTE:
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Tightening torque:
Tightening torque:
Tightening torque:
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
20. Install the water inlet fitting and the thermostat assembly. (Refer to COOLING SYSTEM )
21. Install the water pump assembly. (Refer to COOLING SYSTEM )
22. Install the A/C compressor. (Refer to INSTALLATION
23. Install the cylinder head assembly. (Refer to CYLINDER HEAD )
24. Install the timing chain including the drive belt, the cylinder head cover, the alternator and the timing
chain cover. (Refer to TIMING SYSTEM )
25. Install the intake manifold and exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM )
26. Remove the engine from an engine stand for assembly.
27. Manual transaxle: Install the flywheel (A).
Automatic transaxle: Install the drive plate (A) and the adapter plate (B).
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2012 Hyundai Elantra Limited
2012 ENGINE Engine Cylinder Block - Elantra
Tightening torque:
28. Assemble the transaxle assembly to the engine assembly. (Refer to Automatic Transaxle or Manual
Transaxle System )
29. Install the engine and transaxle assembly to the vehicle. (Refer to ENGINE AND TRANSAXLE
ASSEMBLY )
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