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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Components and components location

Components

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1. Cylinder block 6. Thrust bearing 11. Water jacket insert
2. Ladder frame 7. Main bearing cap 12. Pilot bearing
3. Crankshaft 8. External damper flywheel 13. CKPS wheel
4. Crankshaft upper bearing 9. Crankshaft sproket
5. Crankshaft lower bearing 10. Crankshaft pulley

Cylinder Block External Damper Flywheel Components and

components location
...
Components 1. External damper flywheel ...

Other information:
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft Components and components location

Components

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1. Crankshaft 5. Main bearing cap
2. Crankshaft upper bearing 6. Crankshaft sproket
3. Crankshaft lower bearing 7. Pilot bearing
4. Thrust bearing 8. CKPS wheel

Piston and Connecting Rod Repair procedures Crankshaft Repair procedures

Disassembly • Use fender covers to avoid Disassembly • Use fender covers to avoid
damaging painted surfaces. ... damaging painted surfaces. ...

Other information:

Hyundai Kona (OS) 2018-2019 Owners Manual: Interior general precautions

Prevent chemicals such as perfume, cosmetic oil, sun cream, hand cleaner and air freshener from contacting
the interior parts because they may cause damage or discoloration. If they do contact the interior parts, wipe
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft Repair procedures

Disassembly

• 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. ca
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• Mark all wiring connector and hoses to avoid misconnection. g n.
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• Turn the crankshaft damper pulley so that the No.1 piston is at TDC (Top dead center).
1. Remove the engine and Transaxle Assembly assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly") m
2. Remove the dual clutch transmission.
(Refer to Dual clutch Transmission (DCT) System - "Dual clutch Transmission (DCT)")
3. Remove the external damper flywheel.
(Refer to Cylinder block - "External Damper Flywheel")
4. Remove the rear oil seal.
(Refer to Cylinder block - "Rear Oil Seal")
5. Install the engine to engine stand for disassembly.
6. Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
7. Remove the exhaust manifold.
 (Refer to Intake and Exhaust System - "Exhaust Manifold")
8. Remove the timing chain.
(Refet to Timing System - "Timing Chain")
9. Remove the cylinder head Assembly.
(Refet to Cylindet Head Assembly - "Cylinder Head")
10. Remove the oil pan and oil screen.
(Refer to Lubrication System - "Oil Pan")
11. Remove the oil cooler.
(Refer to Lubrication System - "Engine Oil")
12. Remove the ladder frame.
(Refer to Cylinder Block - "Piston and Connecting Rod")
13. Remove the piston and connecting rod assembly.
(Refer to Cylinder Block- "Piston and Connecting Rod")
14. Check the crankshaft main bearing oil clearance.
15. Remove the main bearing caps (A).

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16. Check the crankshaft end play.
17. Lift the crankshaft (A) out of the cylinder block, being careful not to damage journals.

• Arrange the main bearings and thrust bearings in the correct order.
• Keep the main bearing caps with their bearings assembled together.
Inspection
1. Check the crankshaft main bearing oil clearance.
(1) To check main bearing-to-journal oil clearance, remove the bearing caps with their lower bearings.
(2) Clean each main journal and lower bearing with a clean shop towel.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearing caps with their lower bearings, then tighten the bolts.
Tightening torque :
[17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft)] + [88° - 92°]

• Do not reuse the crankshaft main bearing cap.

• Do not turn the crankshaft.

(5) Remove the bearing caps with their lower bearing again, and measure the widest part of the plastigage.
Bearing oil clearance :
No.1, 2, 3, 4, 5 : 0.020 - 0.041 mm (0.0007 - 0.0016 in)

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(6) 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.

• 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. Recheck
the oil clearance.

• If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

• If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with solvent or detergent.

Cylinder block crankshaft journal bore mark location

Letters have been stamped on the side surface of the block as a mark for the size of each of the 5 main
journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the
correct bearings.

Discrimination Of Cylinder Block Crankshaft Journal Bore

Mark Cylinder block crankshaft journal bore inner diameter
A 52.000 - 52.006 mm (2.0472 - 2.0475 in)
B 52.006 - 52.012 mm (2.0475 - 2.0477 in)

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C 52.012 - 52.018 mm (2.0477 - 2.0479 in)

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Crankshaft Main Journal Mark Location

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Discrimination Of Crankshaft Main Journal
Mark Crankshaft main journal outer diameter
47.954 - 47.960 mm
A
(1.8879 - 1.8882 in)
47.948 - 47.954 mm
B
(1.8877 - 1.8879 in)
47.942 - 47.948 mm
C
(1.8875 - 1.8877 in)
 Crankshaft Main Bearing Color Location

Discrimination Of Crankshaft Main Bearing

Crankshaft main bearing thickness
Mark Color
No.1, 2, 3, 4, 5
2.026 - 2.029 mm
A Blue
(0.0798 - 0.0799 in)
2.023 - 2.026 mm
B Black

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(0.0796 - 0.0798 in)
2.020 - 2.023 mm

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C None
(0.0795 - 0.0796 in)

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2.017 - 2.020 mm

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D Green
(0.0794 - 0.0795 in)

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2.014 - 2.017 mm
E Red / Yellow

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(0.0793 - 0.0794 in)

(8) Select the bearing by using selection table.

Crankshaft Main Bearing Selection Table

Cylinder block crankshaft journal bore mark
Assembling Classification Of Bearing
A B C
E D C
1
(Red / Yellow) (Green) (None)
Crank shaft main D C B
2
journal mark (Green) (None) (Black)
C B A
3
(None) (Black) (Blue)

2. Check the crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a
screwdriver.
Crankshaft end play
 Standard : 0.05 - 0.25 mm (0.0020 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
Reassembly

• Thoroughly clean all parts to 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. Install the crankshaft main bearings.

• 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 five upper bearings(A).

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(2) Align the bearing claw with the claw groove of the main bearing cap (B), and push in the 5 lower

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bearings (A).

(3) Apply a coat of engine oil after assembling the main bearings.
2. Install the thrust bearing.
Install the thrust bearing (A) on the No.3 journal position of the cylinder block with the oil grooves facing
outward.
3. Place the crankshaft on the cylinder block.

• When exchanging the crack shaft and short engine, apply if the pilot bearing is not assembled.
• When press fitting the pilot bearing, press fit so that the load is applied only to the outer race of
the pilot bearing.
– If load is applied to the seal and inner race, the component or bearing inside may be damaged.

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• Press-fit depth of the pilot bearing: 1.5 - 2.0mm (0.0591 - 0.0787 in) from the end of the crank
auto bore.

4. Install the main bearing caps and tighten the cap bolts.

• Do not reuse the main bearing cap bolt.

• Fasten the main bearing cap bolt in two stages.
 • Replace the main bearing cap bolt if it is damaged or deformed.
• Mount the main bearing cap bolt according to the accurate order.
(1) Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Tightening torque :
[17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft)] + [88 - 92° ]
Using the SST (09221-4A000), tighten the main bearing cap bolts (A).

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(3) Check that the crankshaft turns smoothly.
5. Check the crankshaft end play.
6. Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "Piston and Connecting Rod")
7. Install the ladder frame.
(Refer to Cylinder Block - "Ladder Frame")
8. Install the other parts in the reverse order of disassembly.

In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according
to the pin journal mark on the crankshaft.
• Connecting rod bearing selection.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

Crankshaft Components and components location Cylinder Block Repair procedures

Components 1. Crankshaft 2. Crankshaft Disassembly • Use fender covers to avoid
upper bearing 3. Crankshaft lower bearing 4. damaging painted surfaces. ...
Thrust bearing 5. Main bearing cap 6. Crankshaft
sproket 7. ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Parking Distance Warning Switch Schematic diagrams
Circuit Diagram TERMIANL FUNCTION Pin Descriptoin 17 PDW Mode 21 PDW IND 4 Ground ...

Hyundai Kona (OS) 2018-2019 Owners Manual: System operation

Ventilation 1. Set the mode to the position. 2. Set the air intake control to the outside (fresh) air position. 3.
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / External Damper Flywheel Components and components
location

Components

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1. External damper flywheel

Components and components location External Damper Flywheel Repair procedures

Components 1. Cylinder block 2. Ladder Removal and installation 1. Remove the dual
frame 3. Crankshaft 4. Crankshaft upper bearing 5. clutch transmission. (Refer to Dual Clutch
Crankshaft lower bearing 6. Thrust bearing 7. Main Transmisson (DCT) - "Dual Clutch Transmisson
bearing ... Assembly") ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Hood Latch Release Handle Repair procedures
Replacement 1. Using a socket (B), remove the hood release handle (A). 2. To install, reverse removal
procedure. • ...
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / External Damper Flywheel Repair procedures

Removal and installation

1. Remove the dual clutch transmission.
(Refer to Dual Clutch Transmisson (DCT) - "Dual Clutch Transmisson Assembly")

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2. Remove the external damper fly wheel (A).

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Tightening torque :

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71.5 - 75.5 N.m (7.3 - 7.7 kgf.m, 52.8 - 55.6 lb-ft)

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3. Install in the reverse order of removal.

External Damper Flywheel Components and Water Jacket Seperator Components and
components location components location
Components 1. External damper flywheel ... Components 1. Water Jacket Seperator ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Compressor oil Repair procedures
Oil Specification 1. The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system
requires mineral compressor oil. The two oils must never be mixed. 2. Compressor (PAG) oil varies accor ...
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Piston and Connecting Rod Components and components
location

Components

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1. Piston ring 5. Connecting rod lower bearing
2. Piston 6. Connecting rod bearing cap
3. Connecting rod 7. Piston pin
4. Connecting rod upper bearing 8. Snap ring

Rear Oil Seal Repair procedures Piston and Connecting Rod Repair procedures
Removal 1. Remove the dual clutch Disassembly • Use fender covers to avoid
transmission. (Refer to DCT(Dual clutch damaging painted surfaces. ...
Transmission) System - "DCT (Dual clutch
Transmission)") 2. ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Power Door Lock Switch Repair procedures
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Piston and Connecting Rod Repair procedures

Disassembly

• 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. ca
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• To avoid damage, unplug the wiring connectors carefully while holding the connector portion. gn
• Turn the crankshaft so that the No.1 piston is at TDC (Top dead center).
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1. Remove the engine assembly from the vehicle. om
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2. Remove the transaxle assembly from the engine assembly.
(Refer to DCT(Dual clutch Transmission) System - "DCT (Dual clutch Transmission)")
3. Remove the external damper flywheel (A).
(Refer to Cylinder block - "External Damper Flywheel")
4. Remove the rear oil seal.
(Refer to Cylinder Block - "Rear Oil Seal")
5. Install the engine to engine stand for disassembly.
6. Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
7. Remove the exhaust manifold.
 (Refer to Intake and Exhaust System - "Exhaust Manifold")
8. Remove the timing chain.
(Refer to Timing System - "Timing Chain")
9. Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
10. Remove the oil pan and oil screen.
(Refer to Lubrication System - "Oil Pan")
11. Remove the oil cooler.
(Refer to Lubrication System - "Oil Cooler")
12. Remove the ladder frame (A).

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13. Check the connecting rod side clearance.

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14. Check the connecting rod bearing cap oil clearance.

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15. Remove the piston and connecting rod assembly.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.

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(2) Remove the connecting rod bearing caps (A).

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• Mark the connecting rod and caps to be able to reassemble in the original position and
direction.

(3) Push the piston and connecting rod assembly with upper bearing through the top of the cylinder
block.
 • Keep the connecting rod and caps with the bearings assembled together.
• Arrange the piston and connecting rod assemblies in the correct order.
• Mark the piston and connecting rod assembly to be able to reassemble in the original
position.

16. Check fit between piston and piston pin.

17. Disassemble the piston rings.
(1) Using a piston ring expender, remove the two compression rings.
(2) Remove the side rail and coil spring.

• Arrange the piston rings in the correct order.

18. Remove the piston and connecting rod.

Inspection
Connecting Rod

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1. Check the side clearance between piston and connecting rod.
Using filler gauge, measure the side clearance while moving the connecting rod back and forth.

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Side clearance

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Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)

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Maximum : 0.35 mm (0.0138 in)

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• 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.
(1) Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and lower bearing.
(4) Clean the crankshaft pin journal and bearing.
(5) Place a plastigage across the crankshaft pin journal.
(6) Reinstall the lower bearing and connecting rod cap, and tighten the bolts.
Tightening torque :
 17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 88°-92°

• Do not turn the crankshaft.

• Do not reuse the connection rod cap bolts.

(7) Remove the connecting rod cap.

(8) Measure the plastigage at its widest point.
Standard oil clearance :
0.030 - 0.050 mm (0.0012 - 0.0020 in)

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(9) If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing

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and then install a new bearings with the same color mark.

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Recheck the oil clearance.

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• Do not file, shim on scrape the bearings or the caps to adjust clearance.

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(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck
the oil clearance.

• If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

• If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub
them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting Rod Identification Mark

Connecting Rod Specifications
Class Mark Inside Diameter
45.000 - 45.006 mm
0 A, 0
(1.7717 - 1.7719 in)
45.006 - 45.012 mm
1 B, 00
(1.7719 - 1.7721 in)
45.012 - 45.018 mm
2 C, 000
(1.7721 - 1.7724 in)

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Crankshaft Pin Identification Mark

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Crankshaft Specifications om
Mark Outside Diameter Of Pin
41.966 - 41.972 mm
1
(1.6522 - 1.6524 in)
41.960 - 41.966 mm
2
(1.6520 - 1.6522 in)
41.954 - 41.960 mm
3
(1.6517 - 1.6520 in)

Connecting Rod Bearing Identification Mark

 Connecting Rod Bearing Specifications
Class Mark Thickness Of Bearing
1.514 - 1.517 mm
A Light Blue
(0.0596 - 0.0597 in)
1.511 - 1.514 mm
B Black
(0.0595 - 0.0596 in)
1.508 - 1.511 mm
C White
(0.0594 - 0.0595 in)

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1.505 - 1.508 mm
D Light Green

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(0.0593 - 0.0594 in)

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1.502 - 1.505 mm
E Pink

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(0.0591 - 0.0593 in)

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(11) Use the bearing selection table below to select a suitable connecting rod bearing.

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Selection Chart For Connecting Rod Bearings
Assembling Classification Of Connecting Rod Identification Mark
Bearing A, 0 B, 00 C, 000
E D C
1
(pink) (Light Green) (White)
Crankshaft Pin Journal D C B
2
Indentification Mark (Light Green) (White) (Black)
C B A
3
(White) (Black) (Light Blue)

3. Check the connecting rod.

(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 :
0.05 mm (0.0020 in) or less / 100 mm (3.94 in)
Allowable twist of connecting rod :
0.1 mm (0.0039 in ) or less / 100 mm (3.94 in)

• When the connecting rods installed without bearings, there should be no difference on side
surface.

Piston
1. Clean the 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.

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• Do not use a wire brush.

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2. Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner

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diameter and the piston outer diameter.

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Piston-to-cylinder clearance :
0.02 - 0.04 mm (0.0008 - 0.0016 in)

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(1) Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial

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direction.
Cylinder bore diameter :
77.00 - 77.03 mm (3.0315 - 3.0327 in)

(2) Measure the piston outside diameter at 12.0 mm (0.4724 in) from top land of the piston.
Piston outside diameter :
76.97 - 77.00 mm (3.0303 - 3.0315 in)
3. Select the piston matching with cylinder bore class (match classification mark).
Piston-to-cylinder clearance :
0.02 - 0.04 mm (0.0008 - 0.0016 in)
(1) Check the cylinder bore size mark on the side of the cylinder block.

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Discrimination Of Cylinder Bore Size

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Mark Cylinder bore inner diameter
77.000 - 77.010 mm
A
(3.0315 - 3.0319 in)
77.010 - 77.020 mm
B
(3.0319 - 3.0323 in)
77.020 - 77.030 mm
C
(3.0323 - 3.0327 in)

(2) Check the piston size mark on the piston top face.
 A : Piston diameter grade (A, B, C)
T : T-GDI Engine
6: Displacement (1.6L)
E : Type (Fuel efficiency)
Piston Outer Diameter Difference
Mark Piston outer diameter
76.97 - 76.98 mm
A
(3.0303 - 3.0307 in)
76.98 - 76.99 mm
B

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(3.0307 - 3.0311 in)
76.99 - 77.00 mm

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C
(3.0311 - 3.0315 in)

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Piston Ring

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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 ring groove.
Piston ring side clearance
No.1 ring : 0.04 - 0.08 mm (0.0015 - 0.0031 in)
No.2 ring : 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 ring : 0.1 mm (0.0039 in)
No.2 ring : 0.1 mm ( 0.0039 in)
Oil ring : 0.2 mm (0.0079 in)
 If the clearance is greater than maximum, replace the piston.
2. Inspect the 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.
Piston ring end gap
[Standard]
No.1 ring : 0.14 - 0.24 mm (0.0079 - 0.0094 in)
No.2 ring : 0.30 - 0.45 mm (0.0118 - 0.0177 in)
Oil ring : 0.20 - 0.40 mm (0.0079 - 0.0157 in)
[Limit]
No.1 ring : 0.3 mm (0.0118 in)
No.2 ring : 0.5 mm (0.0197 in)
Oil ring : 0.8 mm (0.0315 in)

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Piston pins
1. Measure the outer diameter of piston pin
Piston pin diameter :
19.997 - 20.000 mm (0.7873 - 0.7874 in)

2. Measure the piston pin-to-piston clearance.

 Piston pin-to-piston clearance :
0.004 - 0.012 mm (0.0002 - 0.0005 in)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner
diameter.
Piston pin-to-connecting rod clearance :
0.005 - 0.014 mm (0.0002 - 0.0006 in)
Reassembly

• Thoroughly clean all parts to 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 connecting rod.
(1) Install the snap ring (A) on one side of the piston pin hole.
(2) Align the piston front mark and the connecting rod front mark.
(3) Insert the piston pin (B) into the piston pin hole and the small end bore of connecting rod.
(4) Install the snap ring (C) on the other side after inserting the piston pin

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(5) The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the
engine.

• Before inserting the piston pin, apply sufficient engine oil on the piston’s outer surface, piston
hole’s inner surface and connecting rod’s small-end bore.
 • When inserting, use caution not to damage or scratch the connecting rods’ small-end hole,
piston’s pin hole and piston pin.
• Mount the snap ring surely so that the snap ring contacts the overall groove of the piston’s pin
hole.
• Assemble so that the cut surface of the snap ring is located within the upper 45° range.
• Do not reuse the snap ring that is unstably fitted.

2. Install the piston rings.

(1) Install the oil ring coil spring and the side rail 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.

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3. Install the connecting rod bearings.

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

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4. Install the piston and connecting rod assembly .

• Before installing the piston, apply a sufficient amount of engine oil to the ring grooves and
cylinder bores
(1) Press the piston rings with a ring compressor and check that the rings are securely in place. Then insert
the piston into the cylinder bore, 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) Install the rod caps with bearings, and tighten the bolts.
Tightening torque :
17.7 - 21.8 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 88 - 92°

• Always use new connecting rod cap bolts.

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5. Check the side clearance between piston and connecting rod.
6. Install the ladder frame.

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(1) Clean the ladder frame.

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To be removed harmful foreign matters, oil, dust and moisture on surface that sealed by sealant.

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(2) Apply the sealant on the ladder frame.
Bead width : 2.5 - 3.5 mm (0.0984 - 0.1378 in)

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• Apply the sealant, (THREE-BOND 1217H or LOCTITE 5900H) on the ladder frame rail
portion and install it with in five minutes.
• If when sealant is applied to cylinder block bottom position, sealant position to be same with
positon that is applied to ladder frame rail position.
• Apply sealant along the inner line of the bolt holes.

(3) Install the ladder frame (A).

Tightening torque :
 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

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7. Assemble the other parts in the reverse order of disassembly.

Piston and Connecting Rod Components and Crankshaft Components and components location
components location
Components 1. Crankshaft 2. Crankshaft
Components 1. Piston ring 2. Piston 3. Connecting upper bearing 3. Crankshaft lower bearing 4.
rod 4. Connecting rod upper bearing 5. Connecting Thrust bearing 5. Main bearing cap 6. Crankshaft
rod lower bearing 6. Connecting rod bearing ... sproket 7. ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Front Door Power Window Regulator Repair procedures
Replacement 1. Remove the front door window glass. (Refer to Front Door - "Front Door Window Glass") 2.
Disconnect the front door power window motor connector (A). 3. Loosen the front ...

Hyundai Kona (OS) 2018-2019 Owners Manual: Scheduled maintenance services

Follow Normal Maintenance Schedule if the vehicle is usually operated where none of the following
conditions apply. If any of the following conditions apply, you must follow the Maintenance Under Severe
Usage Conditions. Repeated driving short distance of less than 8 km (5 miles) in normal tem ...

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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Rear Oil Seal Components and components location

Components

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1. Rear oil seal

Water Jacket Seperator Repair procedures Rear Oil Seal Repair procedures
Remove and Installation 1. Remove the Removal 1. Remove the dual clutch
cylinder head assembly. (Refet to Cylinder Head transmission. (Refer to DCT(Dual clutch
Assembli - "Cylinder Head") 2. Remo ... Transmission) System - "DCT (Dual clutch
Transmission)") 2. ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Rear Driveshaft Components and components location
Components 1. Rear drive shaft (LH) 2. Coupling assembly 3. Rear differential carrier assembly 4. Rear drive
shaft (RH) 5. Propeller shaft assembly ...
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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Rear Oil Seal Repair procedures

Removal
1. Remove the dual clutch transmission.
(Refer to DCT(Dual clutch Transmission) System - "DCT (Dual clutch Transmission)")
2. Remove the external damper flywheel (A).
(Refer to Cylinder block - "External damper flywheel")
3. Remove the rear oil seal (A).

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Installation
1. Install the rear oil seal.
(1) Apply engine oil to a new oil seal lip.
(2) Using the SST (09231-H1100, 09231-2B200) and a hammer, tap in the oil seal until its surface is flush
with the rear oil seal retainer edge.
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• Do not reuse the rear oil seal.

2. Remove the external damper flywheel (A).

(Refer to Cylinder block - "External damper flywheel")
3. Remove the dual clutch transmission.
(Refer to Dual Clutch Transmisson (DCT) - "Dual Clutch Transmisson Assembly")

Rear Oil Seal Components and components location Piston and Connecting Rod Components and
components location
Components 1. Rear oil seal ...
Components 1. Piston ring 2. Piston 3. Connecting
rod 4. Connecting rod upper bearing 5. Connecting
rod lower bearing 6. Connecting rod bearing ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Input shaft speed sensor 1 Specifications
Specification Item Specification Type Hall effect sensor Operation condition -40 to 257°F (-40 to 125°C)
Output signal (mA) High: 11.8 - 16.8 Low: 5.9 - 8. ...

Hyundai Kona (OS) 2018-2019 Service Manual: Components and components location
Components The following is the configuration of the FCA system. – Detection device (radar and camera)
that can recognize potential obstacles in the front. – Human-Machine Interface (HMI) to warn driver or
change settings. ...

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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Water Jacket Seperator Components and components location

Components

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1. Water Jacket Seperator

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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Water Jacket Seperator Repair procedures

Remove and Installation

1. Remove the cylinder head assembly.
(Refet to Cylinder Head Assembli - "Cylinder Head")
2. Remove the water jacket seperator (A).

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• Be careful not to deform or damage it when removing.

3. Install in the reverse order of removal.

Water Jacket Seperator Components and Rear Oil Seal Components and components location
components location
Components 1. Rear oil seal ...
Components 1. Water Jacket Seperator ...

Other information:

Hyundai Kona (OS) 2018-2019 Service Manual: Specifications

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Hyundai Kona (OS) 2018-2019 Service Manual / Engine Mechanical System / Cylinder Block / Cylinder Block Repair procedures

Disassembly

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature (20°C [68°F]) 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. ca
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• To avoid damage, unplug the wiring connectors carefully while holding the connector portion. gn
• Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on
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compression stroke.
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1. Remove the engine and transaxle assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
2. Remove the dual clutch transmission.
(Refer to DCT(Dual clutch Transmission) System - "DCT (Dual clutch Transmission)")
3. Remove the external damper flywheel.
(Refer to Cylinder block - "External Damper Flywheel")
4. Remove the rear oil seal.
(Refer to Cylinder block - "Rear Oil Seal")
5. Install the engine to engine stand for disassembly.
6. Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
7. Remove the Exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
8. Remove the timing chain.
(Refet to Timing System - "Timing Chain")
9. Remove the cylinder head Assembly.
(Refet to Cylindet Head Assembly - "Cylinder Head")
10. Remove the oil pan and oil screen.
(Refer to Lubrication System - "Oil Pan")
11. Remove the oil cooler.
(Refer to Lubrication System - "Engine Oil")
12. Remove the oil pressure switch.
(Refer to Lubrication System - "Oil Pressure Switch")
13. Remove the water inlet fitting and thermostat.
(Refer to Cooling System - "Thermostat")
14. Remove the crankshaft position sensor.
(Refer to Engine Control/Fuel System - "Crankshaft Position Sensor (CKPS)")
15. Remove the ladder frame.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
16. Check the connecting rod side clearance.

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(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

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17. Check the connecting rod bearing cap oil clearance.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

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18. Remove the piston and connecting rod assemblies.

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(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

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19. Check the main bearing oil clearance.

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(Refer to Cylinder Block Assembly - "Crankshaft")
20. Check the crankshaft end play.
(Refer to Cylinder Block Assembly - "Crankshaft")
21. Remove the crankshaft.
(Refer to Cylinder Block Assembly - "Crankshaft")
22. Remove the knock sensor.
(Refer to Engine Control/Fuel System - "Knock Sensor (KS)")
Inspection
1. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of 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 :
Less than 0.05 mm (0.0020 in) for total area
Less than 0.02 mm (0.0008 in) for a section of 100 mm x 100 mm (3.9370 in x 3.9370 in)
4. Visually check for scratches on the inside surface of the cylinder bore and replace the cylinder block if any
noticeable scratch is detected.
If deep scratchs are present, replace the cylinder block.
5. Using the cylinder bore gauge, measure the cylinder bore’s inner diameter to the axial and axial
perpendicular directions.
Cylinder bore diameter :

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77.00 - 77.03 mm (3.0315 - 3.0327 in)

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Reassembly
1. Install in the reverse order of disassembly.

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 Assembly - "Crankshaft")
• Piston selection
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

Crankshaft Repair procedures Cooling System

Disassembly • Use fender covers to avoid ...
damaging painted surfaces. ...

Other information: