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Home >> Hyundai >> 2011 >> Elantra GLS, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Cylinder Block >> Cylinder Block >> Repair Procedures >> Disassembly

Repair Procedures: Disassembly

Engine removal is required for this procedure.

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature 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.
NOTE:
  • Mark all wiring and hoses to avoid misconnection.
  • Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).
  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 MT or AT group)
  3. Manual transaxle: Remove the flywheel (A).
    Fig 1: Identifying Flywheel
    G07263770Courtesy of HYUNDAI MOTOR CO.

    Automatic transaxle: Remove the drive plate (A) and the adapter plate (B).

    Fig 2: Identifying Drive Plate
    G07263771Courtesy of HYUNDAI MOTOR CO.
  4. Fix the engine to an engine stand for disassembly.
  5. Remove the intake manifold and exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM in this group)
  6. Remove the timing chain including the drive belt, the cylinder head cover, the alternator and the timing chain cover. (Refer to TIMING SYSTEM in this group)
  7. Remove the cylinder head assembly. (Refer to CYLINDER HEAD in this group)
  8. Remove the A/C compressor. (Refer to REMOVAL )
  9. Remove the water pump assembly. (Refer to COOLING SYSTEM in this group)
  10. Remove the water inlet fitting and the thermostat assembly. (Refer to COOLING SYSTEM in this group)
  11. Remove the knock sensor (A).
  12. Remove the OPS (Oil pressure switch) (B).
  13. Remove the CKPS (Crankshaft position sensor) (C).
    Fig 3: Identifying Knock Sensor
    G07263772Courtesy of HYUNDAI MOTOR CO.
  14. Remove the oil filter. (Refer to LUBRICATION SYSTEM in this group)
  15. Remove the oil screen. (Refer to LUBRICATION SYSTEM in this group)
  16. Remove the rear oil seal (A).
    Fig 4: Identifying Rear Oil Seal
    G07263773Courtesy of HYUNDAI MOTOR CO.
  17. Remove the lower crankcase.
    1. Remove the lower crankcase mounting bolts.
      Fig 5: Identifying Lower Crankcase Mounting Bolts
      G07263774Courtesy of HYUNDAI MOTOR CO.
    2. Remove the main bearing cap bolts.
      Fig 6: Identifying Main Bearing Cap Bolts
      G07263775Courtesy of HYUNDAI MOTOR CO.
  18. Check the connecting rod side clearance.
  19. Check the connecting rod bearing oil clearance.
  20. Remove piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Push the piston and connecting rod assembly with 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.
  21. Check the connecting rod bearing oil clearance.
  22. Check the crankshaft end play.
  23. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    Fig 7: Lifting Crankshaft
    G07263776Courtesy of HYUNDAI MOTOR CO.
    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.
      NOTE: Arrange the piston rings in the correct order.
  26. Remove the snap rings and then disassemble the connecting rod from the piston.
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