Veracruz 2010

2010 Hyundai Veracruz GLS
2010 ENGINE General Information (Engine Mechanical) - Veracruz
2010 ENGINE
General Information (Engine Mechanical) - Veracruz
SPECIFICATIONS
ENGINE SPECIFICATION
Description Specifications Limit
General
Type V-type, DOHC -
Number of cylinders 6 -
Bore 96 mm (3.7795 in) -
Stroke 87.0 mm (3.4252 in) -
Total displacement 3,778 cc (230.55 -
cu.in.)
Compression ratio 10.4 -
Firing order 1-2-3-4-5-6 -
Idle RPM 710 RPM -
Valve timing
Intake Opens (ATDC) 10° -
Closes (ABDC) 62° -
Exhaust Opens (BBDC) 42° -
Closes (ATDC) 6° -
Cylinder head
Flatness of gasket surface Less than 0.05 mm -
(0.0019 in.)
[Less than 0.02 mm
(0.0008 in.)/150x150]
Flatness of Intake Less than 0.1 mm -
manifold (0.0039 in.)
mounting [Less than 0.03 mm
(0.001 in)/110x110]
Exhaust Less than 0.1 mm -
(0.0039 in.)
[Less than 0.03 mm
(0.001 in)/110x110]
Camshaft
Cam height LH Camshaft Intake 46.8 mm (1.8425 in.) -
Exhaust 45.8 mm (1.8031 in.) -
RH Camshaft Intake 46.8 mm (1.8425 in.) -
Exhaust 45.8 mm (1.8031 in.) -
Journal outer LH, RH camshaft Intake No. 1: 27.964 ~ -
diameter 27.978 mm (1.1009 ~
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1.1015 in.)
No. 2, 3, 4: 23.954 ~
23.970 mm (0.9430 ~
0.9437 in.)
Exhaust No. 1: 27.964 ~ -
27.978 mm (1.1009 ~
1.1015 in.)
No. 2, 3, 4: 23.954 ~
23.970 mm (0.9430 ~
0.9437 in.)
Bearing oil LH, RH camshaft Intake No. 1: 0.027 ~ 0.057 -
clearance mm (0.0011 ~ 0.0022
in.)
No. 2, 3, 4: 0.030 ~
0.067 mm (0.0012 ~
0.0026 in.)
Exhaust No. 1: 0.027 ~ 0.057 -
mm (0.0011 ~ 0.0022
in.)
No. 2, 3, 4: 0.030 ~
0.067 mm (0.0012 ~
0.0026 in.)
End play 0.02 ~ 0.18 mm -
(0.0008 ~ 0.0071 in.)
Valve
Valve length Intake 105.27 mm (4.1445 -
in.)
Exhaust 105.50 mm (4.1535 -
in.)
Stem outer Intake 5.465 ~ 5.480 mm -
diameter (0.2151 ~ 0.2157 in.)
Exhaust 5.458 ~ 5.470 mm -
(0.2149 ~ 0.2153 in.)
Face angle 45.25° ~ 45.75° -
Thickness of Intake 1.56 ~ 1.86 mm -
valve head (0.06142 ~ 0.07323
(margin) in.)
Exhaust 1.73 ~ 2.03 mm -
(0.06811 ~ 0.07992
in.)
Valve stem to Intake 0.020 ~ 0.047 mm 0.07 mm (0.00275 in.)
valve guide (0.00078 ~ 0.00185
clearance in.)
Exhaust 0.030 ~ 0.054 mm 0.09 mm (0.00354 in.)
(0.00118 ~ 0.00212
in.)
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Valve guide
Inner diameter Intake 5.500 ~ 5.512 mm -
(0.2165 ~ 0.2170 in.)
Exhaust 5.500 ~ 5.512 mm -
(0.2165 ~ 0.2170 in.)
Length Intake 41.8 ~ 42.2 mm -
(1.6457 ~ 1.6614 in.)
Exhaust 41.8 ~ 42.2 mm -
(1.6457 ~ 1.6614 in.)
Valve seat
Width of seat Intake 1.15 ~ 1.45 mm -
contact (0.05118 ~ 0.05709
in.)
Exhaust 1.35 ~ 1.65 mm -
(0.05315 ~ 0.06496
in.)
Seat angle Intake 44.75° ~ 45.20° -
Exhaust 44.75° ~ 45.20° -
Valve spring
Free length 43.86 mm (1.7267 in.) -
Load 19.3 ± 0.8 kg/34.0 -
mm (42.7 ± 1.8
lb/1.3386 in.)
42.3 ± 1.3 kg/24.2
mm (93.3 ± 2.9
lb/0.9527 in.)
Out of squareness Less than 1.5° -
MLA
MLA outer Intake 34.964 ~ 34.980 mm -
diameter (1.3765 ~ 1.3772 in.)
Exhaust 34.964 ~ 34.980 mm -
(1.3765 ~ 1.3772 in.)
Cylinder head Intake 35.000 ~ 35.025 mm -
tappet bore inner (1.3779 ~ 1.3789 in.)
diameter Exhaust 35.000 ~ 35.025 mm -
(1.3779 ~ 1.3789 in.)
MLA to tappet Intake 0.020 ~ 0.061 mm 0.07 mm (0.0027 in.)
bore clearance (0.0008 ~ 0.0024 in.)
Exhaust 0.020 ~ 0.061 mm 0.07 mm (0.0027 in.)
(0.0008 ~ 0.0024 in.)
Valve clearance
Intake 0.17 ~ 0.23 mm 0.10 ~ 0.30 mm (0.0039 ~
(0.0067 ~ 0.0090 in.) 0.0118 in.)
Exhaust 0.27 ~ 0.33 mm 0.20 ~ 0.40 mm (0.0078 ~
(0.0106 ~ 0.0129 in.) 0.0157 in.)

Cylinder block
Cylinder bore 96.00 ~ 96.03 mm -
(3.7795 ~ 3.7807 in.)
Flatness of gasket surface Less than 0.05 mm -
(0.0019 in.)
[Less than 0.02 mm
(0.0008 in.)/150x150]
Piston
Piston outer diameter 95.96 ~ 95.99 mm -
(3.7779 ~ 3.7791 in.)
Piston to cylinder clearance 0.03 ~ 0.05 mm -
(0.0012 ~ 0.0020 in.)
Ring groove No. 1 ring groove 1.22 ~ 1.24 mm 1.26 mm (0.0496 in.)
width (0.0480 ~ 0.0488 in.)
No. 2 ring groove 1.22 ~ 1.24 mm 1.26 mm (0.0496 in.)
(0.0480 ~ 0.0488 in.)
Oil ring groove 2.01 ~ 2.03 mm 2.05 mm (0.0807 in.)
(0.0791 ~ 0.0799 in.)
Piston ring
Side clearance No. 1 ring 0.03 ~ 0.07 mm 0.1 mm (0.004 in.)
(0.0012 ~ 0.0027 in.)
No. 2 ring 0.03 ~ 0.07 mm 0.1 mm (0.004 in.)
(0.0012 ~ 0.0027 in.)
Oil ring 0.06 ~ 0.15 mm 0.2 mm (0.008 in.)
(0.0024 ~ 0.0059 in.)
End gap No. 1 ring 0.17 ~ 0.32 mm 0.6 mm (0.0236 in.)
(0.0067 ~ 0.0126 in.)
No. 2 ring 0.32 ~ 0.47 mm 0.7 mm (0.0275 in.)
(0.0126 ~ 0.0185 in.)
Oil ring 0.20 ~ 0.70 mm 0.8 mm (0.0315 in.)
(0.0078 ~ 0.0275 in.)
Piston pin
Piston pin outer diameter 23.001 ~ 23.006 mm -
(0.9055 ~ 0.9057 in.)
Piston pin hole inner diameter 23.016 ~ 23.021 mm -
(0.9061 ~ 0.9063 in.)
Piston pin hole clearance 0.01 ~ 0.02 mm -
(0.0004 ~ 0.0008 in.)
Connecting rod small end inner diameter 22.974 ~ 22.985 mm -
(0.9045 ~ 0.9049 in.)
Connecting rod small end hole clearance -0.032 ~ -0.016 mm (- -
0.0012 ~ 0.0006 in.)
Connecting rod
Connecting rod big end inner diameter 58.000 ~ 58.018 mm -

(2.2834 ~2.2842 in.)
Connecting rod bearing oil clearance 0.038 ~ 0.056 mm -
(0.0015 ~ 0.0022 in.)
Side clearance 0.1 ~ 0.25 mm -
(0.0039 ~ 0.0098 in.)
Crankshaft
Main journal outer diameter 68.942 ~ 68.960 mm -
(2.7142 ~ 2.7149 in.)
Pin journal outer diameter 54.954 ~ 54.972 mm -
(2.1635 ~ 2.1642 in.)
Main bearing oil clearance 0.022 ~ 0.040 mm -
(0.0008 ~ 0.0016 in.)
End play 0.10 ~ 0.28 mm -
(0.0039 ~ 0.0110 in.)
Oil pump
Relief valve opening pressure 450 ~ 550 kPa (4.59 ~ -
5.61 kgf/cm2 , 65.28 ~
79.79 psi)
Engine oil
When replacing a short
6.0L (6.34 US qt, 5.28
Total engine or a block
lmp qt)
assembly
Oil quantity Oil pan 5.5L (5.81 US qt, 4.84 -
lmp qt)
Drain and refill 5.2L (5.49 US qt, 4.58 Including oil filter
lmp qt)
5W-20/GF4&SM If not available, refer to
the recommended API or
Recommendation
ILSAC classification and
SAE viscosity number.
API SL, SM or above Satisfy the requirement of
Oil grade
Classification ILSAC GF3, GF4 or the API or ILSAC
above classification.
Recommended SAE Refer to the
SAE viscosity grade viscosity number LUBRICATION
SYSTEM
Oil pressure (at 1000 rpm) 130 kPa (1.32 -
2
kg/cm , 18.77 psi) or
above Oil temperature
in oil pan: 110 ± 2°C
(230 ± 36°F)
Cooling system
Cooling method Forced circulation -
with electrical fan

Coolant quantity 8.5 ~ 10.5 L (8.98 ~ -
11.10 U.S. qts, 7.48 ~
9.24 lmp.qts)
Thermostat Type Wax pellet type -
Opening temperature 82 ± 2°C (179.6 ± -
35.6°F)
Fully opened temperature 95°C (203°F) -
Full lift 10 mm (0.3937 in.) -
MIN
Radiator cap Main valve opening pressure 93.16 ~ 122.58 kpa -
(0.95 ~ 1.25 kg/cm2 ,
13.51 ~ 17.78 psi)
Vacuum valve opening pressure 0.98 ~ 4.90 kpa (0.01 -
~ 0.05 kg/cm2 , 0.14 ~
0.71 psi)
Water temperature sensor
Type Thermistor type -
Resistance 20°C (68°F) 2.31 ~ 2.59 Kohms -
80°C (176°F) 0.3222 Kohms -
TIGHTENING TORQUES
TIGHTENING TORQUES SPECIFICATION

Item Quantity N.m kgf.m lb-ft
Crankshaft pulley 1 284.2 ~ 303.8 29.0 ~ 31.0 209.76 ~ 224.22
bolt
Timing chain cover 17 18.62 ~ 21.56 1.9 ~ 2.2 13.74 ~ 15.91
bolt B
bolt C
bolt D
bolt E
bolt F
bolt G
bolt H
bolt I
bolt J
Cam to cam guide 4 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
bolt
Timing chain auto 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
tensioner bolt
Timing chain auto 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
tensioner nut
Timing chain guide 4 19.60 ~ 24.50 2.0 ~ 2.5 14.17 ~ 18.08
bolt
Oil pump chain 3 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
cover bolt
Oil pump chain 1 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
tensioner bolt
Oil pump chain 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
guide bolt
Oil pump chain 1 18.62 ~ 21.56 1.9 ~ 2.2 13.74 ~ 15.91
sprocket bolt
Lower oil pan bolt 13 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Drive belt auto 1 81.4 ~ 85.3 8.3 ~ 8.7 60.0 ~ 62.9
tensioner bolt (M12)
Drive belt auto 1 17.64 ~ 21.56 1.8 ~ 2.2 13.02 ~ 15.91
tensioner bolt (M8)
Drive belt idler bolt 1 53.90 ~ 57.82 5.5 ~ 5.9 39.78 ~ 42.67
OCV (oil control 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
valve) bolt
Cylinder head bolt 16 (37.3 ~ 41.2) + (118 (3.8 ~ 4.2) + (118 ~ (27.5 ~ 30.4) + (118
~ 122°) + (88 ~ 92°) 122°) + (88 ~ 92°) ~ 122°) + (88 ~ 92°)
Cylinder head bolt 1 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
CVVT & exhaust 4 64.68 ~ 76.44 6.6 ~ 7.8 47.74 ~ 56.42
cam sprocket bolt
Camshaft bearing 32 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
cap bolt
Cylinder head cover 38 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
bolt
Connecting rod 12 (17.7 ~ 21.6) + (1.8 ~ 2.2) + (88 ~ (13.0 ~ 15.9) +
bearing bolt (88~92°) 92°) (88~92°)
Main bearing cap 8 49.00 + 90° 5.0 + 90° 36.16 + 90°
inner bolt (M11)
Main bearing cap 8 19.60 + 120° 2.0 + 120° 14.46 + 120°
outer bolt (M8)
Main bearing cap 6 29.40 ~ 31.36 3.0 ~ 3.2 21.70 ~ 23.14
side bolt (M8)
Oil drain cover bolt 6 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Rear oil seal case 6 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
bolt
Baffle plate bolt 12 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Upper oil pan bolt 16 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Knock sensor bolt 2 15.68 ~ 23.52 1.6 ~ 2.4 11.57 ~ 17.36
Drive plate bolt cap 8 71.54 ~ 75.46 7.3 ~ 7.7 52.80 ~ 55.69
Oil filter cap - 24.50 2.5 18.08
Oil drain bolt cap 1 34.30 ~ 44.10 3.5 ~ 4.5 25.31 ~ 32.55
Oil pump bolt 3 20.6 ~ 22.6 2.1 ~ 2.3 15.2 ~ 16.6
Oil filter body bolt 10 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Oil filter body cover 11 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
bolt
Water vent hose bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
(Timing chain cover
bolt L)
Water pump bolt 1 21.56 ~ 26.46 2.2 ~ 2.7 15.91 ~ 19.53
(Timing chain cover
bolt K)
Water pump bolt 4 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Water pump pulley 4 7.84 ~ 9.80 0.8 ~ 1.0 5.78 ~ 7.23
bolt
Water temp. control 4 19.6 ~ 23.52 2.0 ~ 2.4 14.5 ~ 17.36
nut
Water temp. control 2 19.6 ~ 23.52 2.0 ~ 2.4 14.5 ~ 17.36
bolt
Water inlet pipe bolt 3 16.66 ~ 19.60 1.7 ~ 2.0 12.30 ~ 14.47
Air vent pipe bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Intake manifold bolt 6 26.5 ~ 31.4 2.7 ~ 3.2 19.5 ~ 23.1
Intake manifold nut 2 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Surge tank bolt (M8 3 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
x 25)
Surge tank bolt (M6 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
x 106)
Surge tank nut 1 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
Breather pipe bolt 2 9.80 ~ 11.76 1.0 ~ 1.2 7.23 ~ 8.68
Surge tank bracket 2 27.44 ~ 31.36 2.8 ~ 3.2 20.25 ~ 23.14
bolt rear (M10 x 18)
Surge tank bracket 2 18.62 ~ 23.52 1.9 ~ 2.4 13.74 ~ 17.36
bolt front (M8 x 16)
ETC bracket bolt 2 15.68 ~ 25.48 1.6 ~ 2.6 11.57 ~ 18.80
Exhaust manifold 16 39.20 ~ 44.10 4.0 ~ 4.5 28.93 ~ 32.55
nut
Heat proctor bolt 8 16.66 ~ 21.56 1.7 ~ 2.2 12.30 ~ 15.91
Front muffler 2 39.20 ~ 58.80 4.0 ~ 6.0 28.93 ~ 43.40
REPAIR PROCEDURES
INSPECTION
Compression Pressure
NOTE: If the there is lack of power, excessive oil consumption or poor fuel economy,
measure the compression pressure.
1. Warm up and stop engine.
Allow the engine to warm up to normal operating temperature.
2. Remove the surge tank.

3. Remove the ignition coil connectors (A) and ignition coils (B).
Fig. 1: Identifying Ignition Coil Connectors

Courtesy of HYUNDAI MOTOR CO.
4. Remove the spark plugs.
Using a 16 mm plug wrench, remove the 6 spark plugs.
5. Check cylinder compression pressure.

1. Insert a compression gauge into the spark plug hole.
2. Fully open the throttle.
3. After 7 times of cranking the engine, measure the compression pressure.
NOTE: Always use a fully charged battery to obtain engine speed of 250 rpm
or more.
4. Repeat steps 1 through 3 for each cylinder.
NOTE: This measurement must be done in as short a time as possible.
Compression pressure:
1,225 kPa (12.5 kgf/cm2 , 177 psi)
Minimum pressure:
1,078 kPa (11.0 kgf/cm2 , 156 psi)
5. If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat steps 1 through 3 for cylinders with low
compression.
A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are
worn or damaged.
B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage
past the gasket.
6. Reinstall the spark plugs.
7. Install the ignition coil and ignition coil connectors.
8. Install the surge tank.
Valve Clearance Inspection and Adjustment
NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant
temperature: 20°C) and cylinder head is installed on the cylinder block.
1. Remove the engine cover.

2. Remove air cleaner assembly.
3. Remove the surge tank.
4. Remove the cylinder head cover.
1. Disconnect the ignition coil connector and remove the ignition coil.
2. Disconnect the breather pipe assembly (A) from the intake manifold.
Fig. 2: Identifying Breather Pipe Assembly

3. Loosen the cylinder head cover bolts and then remove the cover (A) and gasket.
Fig. 3: Identifying Cover

5. Set No. 1 cylinder to TDC/compression.

1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain
cover.
Fig. 4: Identifying Mark On Crankshaft Pulley

2. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head
surface as shown below.
If not, turn the crankshaft one revolution (360°)
NOTE: Do not rotate engine counterclockwise
Fig. 5: Identifying Mark On Camshaft Timing Sprockets

6. Inspect the valve clearance.

1. Check only the valve indicated as shown. [No. 1 cylinder: TDC/Compression] measure the valve
clearance.
Fig. 6: Identifying Timing Mark

Measurement method.
A. Using a thickness gauge, measure the clearance between the tappet and the base circle of
camshaft.
Record the out-of-specification valve clearance measurements. They will be used later to
determine the required replacement adjusting tappet.
Valve clearance
Specification
Engine coolant temperature: 20°C [68°F]
Limit
Intake: 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)
Exhaust: 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)
2. Turn the crankshaft pulley one revolution (360°) and align the groove with timing mark "T" of the
lower timing chain cover.
NOTE: Do not rotate engine counterclockwise
3. Check only valves indicated as shown. [NO. 4 cylinder: TDC/compression]. Measure the valve
clearance. (Refer to procedure step 1)
Fig. 7: Identifying Timing Mark

7. Adjust the intake and exhaust valve clearance.

1. Set the No. 1 cylinder to the TDC/compression.
2. Remove the timing chain.
NOTE: Before removing the timing chain, mark the RH/LH timing chain with
an identification based on the location of the sprocket because the
identification mark on the chain for TDC (Top Dead Center) can be
erased.
3. Remove the camshaft bearing caps (A).
Fig. 8: Identifying Camshaft Bearing Caps

4. Remove the camshaft assembly (A).
Fig. 9: Identifying Camshaft Assembly

5. Remove MLAs.
6. Measure the thickness of the removed tappet using a micrometer.
Fig. 10: Measuring Thickness Of Removed Tappet Using Micrometer

7. Calculate the thickness of a new tappet so that the valve clearance comes within the specified
value.
Valve clearance
T: Thickness of removed tappet
A: Measured valve clearance
N: Thickness of new tappet
Intake: N = T + [A - 0.20 mm (0.0079 in.)]
Exhaust: N = T + [A - 0.30 mm (0.0118 in.)]
8. Select a new tappet with a thickness as close as possible to the calculated value.
NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 in.)

from 3.00 mm (0.118 in.) to 3.600 mm (0.1417 in.)
9. Place a new tappet on the cylinder head.
NOTE: Apply engine oil at the selected tappet on the periphery and top
surface.
10. Install the intake and exhaust camshaft.

11. Install the bearing caps (Refer to INSTALLATION ).
12. Install the timing chain (Refer to INSTALLATION ).
13. Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket
and camshaft sprocket timing marks (A).
Fig. 11: Identifying Camshaft Sprocket Timing Marks

14. Recheck the valve clearance.
Valve clearance
[Specification]
Intake: 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)
Exhaust: 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)
TROUBLESHOOTING
PROBLEM SYMPTOMS
Symptom Suspect Area Remedy
Engine misfire with abnormal Worn crankshaft bearings. Loose or Replace the crankshaft and
internal lower engine noises. damaged engine drive plate. bearings as required. Repair or
replace the drive plate as
required.
Worn piston rings. (Oil consumption Inspect the cylinder for a loss of
may or may not cause the engine to compression. Repair or replace
misfire.) as required.
Worn crankshaft thrust bearings Replace the crankshaft and
bearings as required.
Engine misfire with abnormal Stuck valves. (Carbon buildup on the Repair or replace as required.
valve train noise. valve stem)
Excessive worn or mis-aligned timing Replace the timing chain and
chain. sprocket as required.
Worn camshaft lobes. Replace the camshaft and valve
lifters.
Engine misfire with coolant Faulty cylinder head gasket Inspect the cylinder head
consumption. and/or cranking or other damage and engine block for
to the cylinder head and engine damage to the coolant
block cooling system. passages and/or a faulty
Coolant consumption may or head gasket.
may not cause the engine to Repair or replace as
overheat. required.
Engine misfire with excessive Worn valves, guides and/or valve stem Repair or replace as required.
oil consumption. oil seals.
Worn piston rings. (Oil consumption Inspect the cylinder for a
may or may not cause the engine to loss of compression.
misfire)
Repair or replace as
required.
Engine noise on start-up, but Incorrect oil viscosity. Drain the oil.
only lasting a few seconds.
Install the correct
viscosity oil.
Worn crankshaft thrust bearing. Inspect the thrust bearing
and crankshaft.
required.
Upper engine noise, regardless Low oil pressure. Repair or replace as required.
of engine speed. Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain Replace the timing chain and
and/or damaged sprocket teeth. sprockets.

Worn timing chain tensioner, if Replace the timing chain
applicable. tensioner as required.
Worn camshaft lobes. Inspect the camshaft
lobes.
Replace the timing
camshaft and valve lifters
as required.
Worn valve guides or valve stems. Inspect the valves and valve
guides, then repair as required.
Stuck valves. Carbon on the valve Inspect the valves and valve
stem or valve seat may cause the valve guides, then repair as required.
to stay open.
Worn drive belt, idler, tensioner and Replace as required.
bearing.
Lower engine noise, regardless Low oil pressure. Repair as required.
of engine speed. Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the oil Inspect the oil pan.
pump screen.
Inspect the oil pump
screen.
required.
Oil pump screen loose, damaged or Inspect the oil pump
restricted. screen.
required.
Excessive piston-to-cylinder bore Inspect the piston, piston
clearance. pin and cylinder bore.
Repair as required.
Excessive piston pin-to-piston Inspect the piston, piston
clearance. pin and the connecting
rod.
required.
Excessive connecting rod bearing Inspect the following
clearance components and repair as
required.
The connecting rod

bearings.
The connecting rods.
The crankshaft pin
journals.
Excessive crankshaft bearing Inspect the following
clearance. components, and repair as
required.
The crankshaft bearings.

The crankshaft main
journals.
The cylinder block.
Incorrect piston, piston pin and Verify the piston pins and
connecting rod installation connecting rods are
installed correctly.
Repair as required.
Engine noise under load. Low oil pressure Repair or replace as required.
Excessive connecting rod bearing Inspect the following
clearance. components and repair as
required :
The connecting rod

bearings.
The connecting rods.
The crankshaft.
Excessive crankshaft bearing Inspect the following
clearance. components, and repair as
required.
The crankshaft bearings.

The crankshaft main
journals.
The cylinder block.
Engine will not crank-crankshaft Hydraulically locked cylinder. 1. Remove spark plugs and
will not rotate. check for fluid.
Coolant/antifreeze in cylinder.
2. Inspect for broken head
Oil in cylinder. gasket.
Fuel in cylinder. 3. Inspect for cracked engine
block or cylinder head.
4. Inspect for a sticking fuel
injector and/or leaking
fuel regulator.
Broken timing chain and/or timing 1. Inspect timing chain and
chain and/or timing chain gears. gears.
2. Repair as required.
Material in cylinder. 1. Inspect cylinder for

damaged components
Broken valve and/or foreign materials.
Piston material 2. Repair or replace as
Foreign material required.
Seized crankshaft or connecting rod 1. Inspect crankshaft and
bearings. connecting rod bearing.
Bent or broken connecting rod. 1. Inspect connecting rods.
Broken crankshaft. 1. Inspect crankshaft.
SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS DESCRIPTION
Tool (Number and Name) Graphic Use
Crankshaft front oil seal installer Installation of the front oil seal
(09231-3C100)
Flywheel stopper (09231-3C300) Removal and installation of the

flywheel and crankshaft pulley.
Torque angle adapter Installation of bolts & nuts

(09221-4A000) needing an angular method
Valve stem seal remover (09222- Removal of the valve stem seal
29000)
Valve stem seal installer (09222- Installation of the valve stem seal
3C100)
Valve spring compressor & holder Removal and installation of the

(09222-3K000) (09222-3C300) intake or exhaust valves
1. 09222-3K000
2. 09222-3C300 (holder)
Crankshaft rear oil seal installer Installation of the crankshaft rear
(09231-3C200) (09231-H1100) oil seal
1. 09231-3C200
2. 09231-H1100
Oil pan remover (09215-3C000) Removal of oil pan
Oil filter wrench (09263-3C100) Removal and installation of the oil

filter
2010 ENGINE Cylinder Block - Veracruz
2010 ENGINE
Cylinder Block - Veracruz
COMPONENTS AND COMPONENTS LOCATION

COMPONENTS
Fig. 1: Identifying Cylinder Block Components With Torque Specifications


Fig. 2: Identifying Cylinder Block Components With Torque Specifications

REPAIR PROCEDURES
REMOVAL
CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
NOTE: Mark all wiring and hoses to avoid misconnection.
Inspect the timing belt before removing the cylinder head.

Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
Engine removal is required for this procedure.
1. Remove the exhaust manifold.

2. Remove the intake manifold.
4. Remove the water temperature control assembly.
5. Remove the cylinder head.
6. Remove the oil pump.
7. Remove the oil filter assembly.
8. Remove the A/C compressor (A) from engine.
Fig. 3: Identifying A/C Compressor

9. Remove the alternator (A) from engine.
Fig. 4: Identifying Generator

10. Remove the power steering pump from engine.
(Refer to POWER STEERING OIL PUMP ).
DISASSEMBLY
1. Remove the drive plate.

2. Remove the knock sensor (A).
Fig. 5: Identifying Knock Sensor

3. Remove the upper oil pan (A).
Fig. 6: Identifying Upper Oil Pan

4. Remove the baffle plate (A).
Fig. 7: Identifying Baffle Plate

5. Remove the rear oil seal case (A).
Fig. 8: Identifying Rear Oil Seal Case

6. Remove the oil drain cover (A).
Fig. 9: Identifying Oil Drain Cover

7. Check the connecting rod end play.

8. Check the connecting rod cap oil clearance.
9. Remove the piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. 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.
10. Remove the crankshaft main bearing cap and check oil clearance.
11. Check the crankshaft end play.
12. Lift the crankshaft (A) out of engine, being careful not to damage journals.
Fig. 10: Identifying Crankshaft

NOTE: Arrange the main bearings and thrust bearings in the correct order.
13. 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 piston and piston
pin as a set.
14. Remove the piston rings.

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove 2 side rails and the spacer by hand.
NOTE: Arrange the piston rings in the correct order only.
15. Disconnect connecting rod from piston.
Using a press, remove the piston pin from the piston.
(Press-in load : 800 ~ 1400kg (1764 ~ 3086lb)
INSPECTION
Connecting Rod And Crankshaft
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
Standard end play : 0.1~ 0.25mm (0.004 ~ 0.010in.)
Fig. 11: Measuring End Play

A. If out-of-tolerance, install a new connecting rod.

B. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove 2 connecting rod cap bolts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
NOTE: Do not turn the crankshaft.
7. Remove 2 bolts, connecting rod cap and bearinghalf.

8. Measure the plastigage at its widest point.
Standard oil clearance
0.038 ~ 0.056mm (0.0015 ~ 0.0022in.)
Fig. 12: Measuring Plastigage

9. 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.
10. 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.
Connecting Rod Mark Location
Fig. 13: Identifying Connecting Rod Mark

Identification Of Connecting Rod
CONNECTING ROD SPECIFICATION

Class Mark Inside Diameter
0 a 58.000 ~ 58.006mm (2.2834 ~ 2.2837in.)
1 b 58.006 ~ 58.012mm (2.2837 ~ 2.2839in.)
2 c 58.012 ~ 58.018mm (2.2839 ~ 2.2842in.)
Crankshaft Pin Mark Location
Identification of Crankshaft
Fig. 14: Identifying Crankshaft Pin Mark Location

Discrimination of Crankshaft
CRANKSHAFT DISCRIMINATION
Class Mark Outside Diameter of Pin
I 1 or A 54.966 ~ 54.972mm (2.1640 ~ 2.1642in.)
II 2 or B 54.960 ~ 54.966mm (2.1638 ~ 2.1640in.)
III 3 or C 54.954 ~ 54.960mm (2.1635 ~ 2.1638in.)
Place of Identification Mark (Connecting Rod Bearing)
Upper
Fig. 15: Identifying Connecting Rod (Upper) Bearing Mark

Lower
Fig. 16: Identifying Connecting Rod (Lower) Bearing Mark

Identification of Connecting Rod Bearing
CONNECTING ROD BEARING SPECIFICATION

Class Mark Thickness of Bearing
E Blue 1.514 ~ 1.517mm (0.0596 ~ 0.0597in.)
D Black 1.511 ~ 1.514mm (0.0595 ~ 0.0596in.)
C Brown 1.508 ~ 1.511mm (0.0594 ~ 0.0595in.)
B Green 1.505 ~ 1.508mm (0.0593 ~ 0.0594in.)

A Yellow 1.502 ~ 1.505mm (0.0591 ~ 0.0593in)
*(11) Selection
CONNECTING ROD IDENTIFICATION MARK

Connecting Rod Identification Mark
0 (a) 1 (b) 2 (c)
1 or A A (Yellow) B (Green) C (Brown)
Crankshaft Identification Mark 2 or B B (Green) C (Brown) D (Black)
3 or C C (Brown) D (Black) E (Blue)
3. Check the crankshaft bearing oil clearance.

1. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.
Tightening torque
49.00Nm (5.0 kgf.m, 36.16lb-ft) + 90°
19.60 Nm (2.0 kgf.m, 14.46lb-ft) + 120°
29.40 ~ 31.36Nm (3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft)
NOTE: Do not turn the crankshaft.
5. Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.022 ~ 0.040mm (0.0009 ~ 0.0016in.)

6. 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.
7. 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.
NOTE: 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 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.
Fig. 18: Identifying Crankshaft Bore Mark Location

Discrimination of Cylinder Block
CYLINDER BLOCK DISCRIMINATION

Class Mark Inside Diameter
a A 73.500 ~ 73.506mm (2.8937 ~ 2.8939in.)
b B 73.506 ~ 73.512mm (2.8939 ~ 2.8942in.)
c C 73.512 ~ 73.518mm (2.8942 ~ 2.8944in.)
Crankshaft Journal Mark Location
Fig. 19: Identifying Crankshaft Journal Mark Location

CRANKSHAFT DISCRIMINATION
Class Mark Outside Diameter of Journal

I 1 or A 68.954 ~ 68.960mm (2.7147 ~ 2.7150in.)
II 2 or B 68.948 ~ 68.954mm (2.7145 ~ 2.7147in.)
III 3 or C 68.942 ~ 68.948mm (2.7142 ~ 2.7145in.)
Place of Identification Mark (Crankshaft Bearing)
Fig. 20: Identifying Crankshaft Bearing Mark

Discrimination of Crankshaft Bearing
CRANKSHAFT BEARING DISCRIMINATION

Class Mark Thickness of Bearing
E Blue 2.277 ~ 2.280mm (0.0896 ~ 0.0897in.)
D Black 2.274 ~ 2.277mm (0.0895 ~ 0.0896in.)
C Brown 2.271 ~ 2.274mm (0.0894 ~ 0.0895in.)
B Green 2.268 ~ 2.271mm (0.0893 ~ 0.0894in.)
A Yellow 2.265 ~ 2.268mm (0.0892 ~ 0.0893in.)
Selection
CRANKSHAFT BORE IDENTIFICATION MARK

Crankshaft Bore Identification Mark
a (A) b (B) c (C)
1 or A A (Yellow) B (Green) C (Brown)
Crankshaft Identification Mark 2 or B B (Green) C (Brown) D (Black)
3 or C C (Brown) D (Black) E (Blue)
4. 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 ~ 0.28mm (0.0039 ~ 0.0110in.)
Fig. 21: Checking Crankshaft End Play

If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
2.41 ~ 2.45mm (0.0949 ~ 0.0964in.)
5. Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Crank pin diameter :
54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)
Fig. 22: Measuring Diameter Of Main Journal And Crank Pin

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 :
0.05mm/100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm/100mm (0.0039 in./3.94 in.) or less
Cylinder Block
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 0.05mm (0.0020 in.), Less than 0.02mm (0.0008in.)/150 x 150
Fig. 23: Inspecting Surface Of Cylinder Block For Flatness

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
96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)
Fig. 24: Inspecting Cylinder Bore Diameter

6. Check the cylinder bore size code on the cylinder block.
Fig. 25: Identifying Cylinder Bore Size Code On Cylinder Block

CYLINDER BORE SIZE CODE

Class Size Code Cylinder Bore Inner Diameter
A A 96.00~96.01mm (3.7795 ~ 3.7799in.)
B B 96.01~96.02mm (3.7799 ~ 3.7803in.)
C C 96.02~96.03mm (3.7803 ~ 3.7807in.)
7. Check the piston size code (A) and the front mark (B) on the piston top face.
Fig. 26: Identifying Piston Size Code On Piston

PISTON SIZE CODE

Class Size Code Piston Outer Diameter
A A 95.96 ~ 95.97mm (3.7779 ~ 3.7783in.)
B B 95.97 ~ 95.98mm (3.7783 ~ 3.7787in.)
C C 95.98 ~95.99mm (3.7787 ~ 3.7791in.)
8. Select the piston related to cylinder bore class.
Clearance : 0.03 ~ 0.05mm (0.0012 ~ 0.0020in.)
Piston And Rings
1. Clean piston
1. Using a gasket scraper, remove the carbon from the piston top.
2. Using a groove cleaning tool, clean the piston ring grooves.
3. Using solvent and a brush, thoroughly clean the piston.
NOTE: Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of
the piston.
Standard diameter
95.96 ~ 95.99mm (3.7779~ 3.7791in.)
Fig. 27: Measuring Of Piston Outside Diameter

3. Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.03 ~ 0.05mm (0.0012 ~ 0.0020in.)
4. 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 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
No. 2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No. 1 : 0.1mm (0.004in.)
No. 2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
Fig. 28: Measuring Clearance Between Piston Ring And Wall

If the clearance is greater than maximum, replace the piston.
5. 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 ~ 0.32mm (0.0067 ~ 0.0126in.)
No. 2 : 0.32 ~ 0.47m (0.0126 ~ 0.0185in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit
No. 1 : 0.6mm (0.0236in.)
No. 2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
Fig. 29: Checking Piston Ring End Gap

Piston Pins
1. Measure the diameter of the piston pin.
Piston pin diameter
23.001 ~ 23.006mm (0.9056 ~ 0.9057in.)
Fig. 30: Measuring Diameter Of Piston Pin
2. Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.009 ~ 0.017mm (0.0004 ~ 0.0007in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference
-0.032 ~ -0.017mm (-0.0012 ~ -0.0007in.)
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.
1. Assemble the piston and the connecting rod.

1. Use a hydraulic press for installation.
2. The piston front mark and the connecting rod front mark must face the timing belt side of the
engine.
Fig. 31: Checking Difference Between Piston Pin Diameter And Connecting Rod Small End
Diameter
2. Install the piston rings.

1. Install the oil ring spacer and 2 side rails by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
3. Position the piston rings so that the ring ends are as shown in the illustration.
Fig. 32: Identifying Piston Rings

3. Install the connecting rod bearings.

1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
Fig. 33: Identifying Bearings

4. Install the main bearings.
NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings
(A).
Fig. 34: Identifying Lower Bearings

2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower
bearings.
5. 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.
Fig. 35: Identifying Thrust Bearings

6. Place the crankshaft (A) on the cylinder block.
Fig. 36: Identifying Crankshaft

7. Place the main bearing caps on cylinder block.

8. Install the main bearing cap bolts.
1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown in the
illustration.
Tightening torque
Main bearing cap bolt
49.00Nm (5.0 kgf.m, 36.16lb-ft) + 90° (1 ~ 8)
19.60 Nm (2.0 kgf.m, 14.46lb-ft) + 120° (9 ~ 16)
29.40 ~ 31.36Nm (3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft) (17 ~ 22)
NOTE: Always use new main bearing cap bolts.

If any of the bearing cap bolts are broken or deformed, replace
it.
Fig. 37: Identifying Main Bearing Cap Bolt Tightening Sequence

Use the SST (09221-4A000), install main bearing cap bolts.
Fig. 38: Installing Main Bearing Cap Bolts

2. Check that the crankshaft turns smoothly.

9. Check crankshaft end play.
10. Install the piston and connecting rod assemblies.
NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves
and cylinder bores.
1. 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.
2. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment
before pushing the piston into place.
3. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
Use SST (09221-4A000), install connecting rod bearing cap bolts.
Fig. 39: Installing Connecting Rod Bearing Cap Bolts

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.
Fig. 40: Installing Piston


12. Install the oil drain cover (A).
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)
Fig. 41: Identifying Oil Drain Cover

NOTE: Clean the sealing face before assembling two parts.

Remove harmful foreign materials on the sealing face before
applying sealant
Before assembling oil drain cover, the liquid sealant TB1217H should
be applied to the oil drain cover.
The part must be assembled within 5 minutes after sealant was
applied.
Apply sealant to the inner threads of the bolt holes.
Fig. 42: Identifying Sealant Apply Area

13. Install the rear oil seal case (A).
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)
Fig. 43: Identifying Rear Oil Seal Case


applying sealant
Before assembling rear oil seal case, the liquid sealant TB1217H
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.

14. Using the SST (09231-3C200, 09231-H1100), install rear oil seal.
Fig. 45: Identifying Rear Oil Seal

15. Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in the
illustration.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
Fig. 46: Identifying Baffle Plate Bolts Tightening Sequence

16. Install the upper oil pan.

A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm (0.1in.)
Fig. 47: Identifying Upper Oil Pan Liquid Sealant Apply Area

applying sealant
When applying sealant gasket, sealant must not protrude into
the inside of oil pan.
To prevent leakage of oil, apply sealant gasket to the inner
threads of the bolt holes.
C. Install the upper oil pan.
Uniformly tighten the bolts in several passes.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
Fig. 48: Identifying Upper Oil Pan Bolts Tightening Sequence

17. Install the knock sensor (A).
Tightening torque
15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~ 17.36lb-ft)
Fig. 49: Identifying Knock Sensor

18. Install the drive plate.
Tightening torque
71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~ 55.69lb-ft)
INSTALLATION
1. Install the power steering pump.

2. Install the alternator.
3. Install the air conditioner compressor
4. Install the oil filter assembly.
5. Install the oil pump.
6. Install the cylinder head.
7. Install the water temperature control assembly.
8. Install the timing chain.
9. Install the intake manifold.
10. Install the exhaust manifold.
2010 ENGINE Cylinder Head Assembly - Veracruz
2010 ENGINE
Cylinder Head Assembly - Veracruz
COMPONENTS AND COMPONENTS LOCATION

COMPONENTS
Fig. 1: Identifying Cylinder Head Assembly Components With Torque Specifications (1 Of 2)


Fig. 2: Identifying Cylinder Head Assembly Components With Torque Specifications (2 Of 2)

REPAIR PROCEDURES
REMOVAL
CAUTION: Use fender covers to avoid damaging painted surfaces.

To avoid damaging the cylinder head, wait until the engine coolant
temperature drops below normal operating 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 top dead center.
Engine removal is required for this procedure.
1. Remove the exhaust manifold.

2. Remove the intake manifold.
4. Remove the water temperature control assembly.
5. Remove the camshaft bearing cap (A).
Fig. 3: Identifying Camshaft Bearing Cap

6. Remove the camshaft assembly (A).
Fig. 4: Identifying Camshaft Assembly

7. Remove the cylinder head bolts, then remove cylinder head.

1. Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown.
Remove the 16 cylinder head bolts and plate washers.
Fig. 5: Identifying Cylinder Head Bolt Loosening Sequence

CAUTION: Head warpage or cracking could result from removing bolts in

an incorrect order.
2. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden
blocks on a bench.
CAUTION: Be careful not to damage the contact surfaces of the cylinder

head and cylinder block.
DISASSEMBLY
NOTE: Identify MLA, valves and valve springs as they are removed so that each item
can be reinstalled in its original position.
1. Remove the MLAs (A).
Fig. 6: Identifying MLA

2. Remove the valves.

1. Using the SST (09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.
Fig. 7: Compressing Valve Spring

2. Remove the spring retainer.

3. Remove the valve spring.
4. Remove the valve.
5. Using the SST (09222-29000), remove the valve stem seal.
Fig. 8: Removing Valve Stem Seal

NOTE: Do not reuse old valve stem seals.
3. Remove the OCV (A).
Fig. 9: Identifying OCV

INSPECTION
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface
Standard: Less than 0.05 mm (0.002 in.)
[Less than 0.02 mm (0.0008 in.)/150x150]
Flatness of manifold gasket surface
Standard: Less than 0.03 mm (0.001 in)/110x110
Fig. 10: Inspecting For Flatness

2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If
cracked, replace the cylinder head.
Valve And Valve Spring
1. Inspect valve stems and valve guides.

1. Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake/Exhaust: 5.500 ~ 5.512 mm (0.216 ~ 0.217 in.)
Fig. 11: Measuring Inside Diameter Of Valve Guide

2. Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake: 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.)
Exhaust: 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.)
Fig. 12: Measuring Diameter Of Valve Stem

3. Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake: 0.020 ~ 0.047 mm (0.0008 ~ 0.0018 in.)
Exhaust: 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in.)
[Limit]
Intake: 0.07 mm (0.0027 in.)
Exhaust: 0.09 mm (0.0035 in.)
2. Inspect valves.
1. Check the valve is ground to the correct valve face angle.
2. Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
3. Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake: 1.56 ~ 1.86 mm (0.06142 ~ 0.07323 in.)
Exhaust: 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.)
Fig. 13: Checking Valve Head Margin Thickness

4. Check the valve length.
Length
Intake: 105.27 mm (4.1445 in)
Exhaust: 105.50 mm (4.1535 in)
5. Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace
cylinder head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width
should be within specifications and centered on the valve face.
4. Inspect valve springs.

1. Using a steel square, measure the out-of-square of the valve spring.
2. Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height: 43.86 mm (1.7267 in.)
Out-of-square: 1.5°
Fig. 14: Measuring Free Length Of Valve Spring

MLA
1. Inspect MLAs.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust: 34.964 ~ 34.980 mm
(1.3765 ~ 1.3771 in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust: 35.000 ~ 35.025 mm
(1.3779 ~ 1.3789 in.)
3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust: 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.)
[Limit]
Intake/Exhaust: 0.07 mm (0.0027 in.)
Camshaft
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake: 46.8 mm (1.8425 in.)
Exhaust: 45.8 mm (1.8031 in.)
Fig. 15: Measuring Cam Lobe Height Using Micrometer

If the cam lobe height is less than standard, replace the camshaft.
2. Inspect the camshaft journal clearance.

1. Clean the bearing caps and camshaft journals.
2. Place the camshafts on the cylinder head.
3. Lay a strip of plastigage across each of the camshaft journals.
Fig. 16: Laying Strip Of Plastigage Across Of Camshaft Journal

4. Install the bearing caps.
CAUTION: Do not turn the camshaft.
5. Remove the bearing caps.

6. Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No. 1 journal: 0.020 ~ 0.057 mm (0.0008 ~ 0.0022 in.)
No. 2, 3, 4 journal: 0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)
Exhaust
No. 1 journal: 0.020 ~ 0.057 mm (0.0008 ~ 0.0022 in.)
No. 2, 3, 4 journal: 0.030 ~ 0.067 mm (0.0012 ~ 0.0026 in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder
head.
7. Completely remove the plastigage.

8. Remove the camshafts.
3. Inspect the camshaft end play.
1. Install the camshafts.
2. Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value]: 0.02 ~ 0.18 mm (0.0008 ~ 0.0071 in.)
Fig. 18: Measuring End Play Using Dial Indicator

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
3. Remove the camshafts.
CVVT Assembly
1. Inspect the CVVT assembly.

1. Check that the CVVT assembly will not turn.
2. Apply vinyl tape to the retard hole except the one indicated by the arrow in the graphic.
Fig. 19: Identifying Mark

3. Wind tape around the tip of the air gun and apply air of approx. 150 kpa (1.5 kgf/cm2 , 21 psi) to
the port of the camshaft. (Perform this in order to release the lock pin for the maximum delay angle
locking.)
NOTE: When the oil splashes, wipe it off with a shop rag.
4. Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked
direction in the graphic) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying
force by hand.
Fig. 20: Turning CVVT Assembly

5. Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly
turn back and forth and check the movable range and that there is no interference.
Standard: Movable smoothly in the range about 22.5°
6. Turn the CVVT assembly with your hand and lock it at the maximum delay angle position
(clockwise).
REASSEMBLY
NOTE: Thoroughly clean all parts to be assembled. Before installing the parts, apply
fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new
ones.
1. Install the valves.

1. Using the SST (09222-3C100), push in a new oil seal.
NOTE: Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the
valve guides.
Fig. 21: Pushing Oil Seal

2. Install the valve, valve spring and spring retainer.
NOTE: Place valve springs so that the side coated with enamel faces toward
the valve spring retainer and then install the retainer.
3. Using the SST (09222 - 3K000, 09222-3C300), compress the spring and install the retainer locks.
After installing the valves, ensure that the retainer locks are correctly in place before releasing the
valve spring compressor.
Fig. 22: Compressing Spring

4. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer lock.
2. Install the MLAs.
Check that the MLA rotates smoothly by hand.
Fig. 23: Identifying MLA

NOTE: MLA can be reinstalled in its original position.
3. Install the OCV (A).
Tightening torque
9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
Fig. 24: Identifying OCV

NOTE: To install OCV with gray colored connector into RH bank.

To install OCV with black colored connector into LH bank.
CAUTION: Do not reuse the OCV when dropped.

Keep the OCV clean.
Do not hold the OCV sleeve during servicing.
When the OCV is installed on the engine, do not move the
engine while holding the OCV yoke.
INSTALLATION
NOTE: Thoroughly clean all parts to be assembled.

Always use a new head and manifold gasket.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft, set the No. 1 piston at TDC.
1. Install the cylinder head.

A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.
Fig. 25: Identifying Sealant Location

NOTE: Refer to the graphic below to apply the sealant.
Bead width: 2.0 ~ 3.0 mm
Sealant locations: 1.0 ~ 1.5 mm from block surface
Recommended sealant: Liquid sealant TB1217H

C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
Fig. 27: Identifying Sealant On Cylinder Head Gaskets

NOTE: Be careful of the installation direction.
Fig. 28: Identifying Mark

D. Install the cylinder head.
NOTE: Remove the extruded sealant after assembling cylinder heads.
Fig. 29: Identifying Cylinder Head

2. Place the cylinder head carefully to avoid damaging the gasket.

3. Install the cylinder head bolts.
1. Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
2. Using the SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in
several passes, in the sequence shown.
Tightening torque
Head bolt: 37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + 118 ~ 122° + 88 ~ 92°
Bolt (A): 18.62 ~ 23.52 N.m (1.9 ~ 2.4 kgf.m, 13.74 ~ 17.36 lb-ft)
NOTE: Always use new cylinder head bolts.
Fig. 30: Identifying Cylinder Head Bolt Tightening Sequence

Fig. 31: Identifying Bolt

Fig. 32: Installing Cylinder Head Bolts

4. Install the CVVT and camshaft sprocket.
Tightening torque
64.68 ~ 76.44 N.m (6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4 lb-ft)
Fig. 33: Identifying CVVT & Camshaft Sprocket

NOTE: Install camshaft-inlet to dowel pin of CVVT assembly.
At this time, do not install to oil hole of camshaft-inlet.
Hold the hexagonal head wrench portion of the camshaft with a vise,
and install the bolt and CVVT assembly.
Do not rotate CVVT assembly when camshaft is installed to dowel pin
of CVVT assembly.
5. Install the camshafts (A).
NOTE: Apply a light coat of engine oil on camshaft journals.

Assemble the key groove of camshaft rear side to the same level of
head top surface.
Be careful the right, left bank, intake, exhaust side before
assembling.
Fig. 34: Identifying Camshafts

Intake Camshaft
Fig. 35: Identifying Intake Camshaft
INTAKE CAMSHAFT SPECIFICATION

LH RH
A: Ø 30 mm (1.1811 in.) A: Ø 27 mm (1.0630 in.)
B: Ø 27 mm (1.0630 in.) B: Ø 30 mm (1.1811 in.)
Exhaust Camshaft
Fig. 36: Identifying Exhaust Camshaft

EXHAUST CAMSHAFT SPECIFICATION

LH RH
A: Ø 27 mm (1.0630 in.) A: Ø 30 mm (1.1811 in.)
Fig. 37: Identifying Camshaft

CAMSHAFT SPECIFICATION
LH RH
A: Ø 30 mm (1.1811 in.) A: Ø 30 mm (1.1811 in.)
B: Ø 30 mm (1.1811 in.) B: Ø 30 mm (1.1811 in.)
1. Install the camshaft bearing caps as following order.
Tightening torque
1st step: 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
2nd step:
9.80 ~ 11.76 N.m (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)
- 2nd step
Fig. 38: Identifying Camshaft Bearing Caps

NOTE: Be careful the right, left bank, intake, exhaust side, front mark before
assembling.
Fig. 39: Identifying Mark On Cap

A. L (LH), R (RH)
B. I (Intake), None (Exhaust)
C. Journal number
D. Front mark
CAUTION: Rotate the crankshaft so as not to contact the valves to the

pistons by positioning the pistons below 10 mm (0.3937 in.)
from the top of cylinder block.
2. Install the water temperature control assembly.

3. Install the timing chain.
4. Check and adjust valve clearance.
5. Install the exhaust manifold.
6. Install the intake manifold.

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2010 Hyundai Veracruz GLS

2010 ENGINE General Information (Engine Mechanical) - Veracruz

General Information (Engine Mechanical) - Veracruz

jueves, 18 de febrero de 2021 11:50:02

(0.0106 ~ 0.0129 in.) 0.0157 in.)

Connecting rod big end inner diameter 58.000 ~ 58.018 mm -

with electrical fan

TIGHTENING TORQUES SPECIFICATION

1. Warm up and stop engine.

Allow the engine to warm up to normal operating temperature.

2. Remove the surge tank.

Fig. 1: Identifying Ignition Coil Connectors

4. Remove the spark plugs.

Using a 16 mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.

4. Repeat steps 1 through 3 for each cylinder.

NOTE: This measurement must be done in as short a time as possible.

1,225 kPa (12.5 kgf/cm2 , 177 psi)

1,078 kPa (11.0 kgf/cm2 , 156 psi)

Valve Clearance Inspection and Adjustment

1. Remove the engine cover.

Fig. 2: Identifying Breather Pipe Assembly

Fig. 3: Identifying Cover

5. Set No. 1 cylinder to TDC/compression.

Fig. 4: Identifying Mark On Crankshaft Pulley

If not, turn the crankshaft one revolution (360°)

NOTE: Do not rotate engine counterclockwise

Fig. 5: Identifying Mark On Camshaft Timing Sprockets

6. Inspect the valve clearance.

Fig. 6: Identifying Timing Mark

Engine coolant temperature: 20°C [68°F]

Intake: 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)

Exhaust: 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)

NOTE: Do not rotate engine counterclockwise

Fig. 7: Identifying Timing Mark

7. Adjust the intake and exhaust valve clearance.

3. Remove the camshaft bearing caps (A).

Fig. 8: Identifying Camshaft Bearing Caps

4. Remove the camshaft assembly (A).

Fig. 9: Identifying Camshaft Assembly

Fig. 10: Measuring Thickness Of Removed Tappet Using Micrometer

Engine coolant temperature: 20°C [68°F]

T: Thickness of removed tappet

A: Measured valve clearance

N: Thickness of new tappet

Intake: N = T + [A - 0.20 mm (0.0079 in.)]

Exhaust: N = T + [A - 0.30 mm (0.0118 in.)]

NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006 in.)

9. Place a new tappet on the cylinder head.

10. Install the intake and exhaust camshaft.

Fig. 11: Identifying Camshaft Sprocket Timing Marks

14. Recheck the valve clearance.

Engine coolant temperature: 20°C [68°F]

Intake: 0.17 ~ 0.23 mm (0.0067 ~ 0.0090 in.)

Exhaust: 0.27 ~ 0.33 mm (0.0106 ~ 0.0129 in.)

and/or damaged sprocket teeth. sprockets.

The connecting rod

The crankshaft bearings.

The connecting rod

The crankshaft bearings.