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Home >> Hyundai >> 2011 >> Azera GLS >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block >> Repair Procedures >> Inspection >> Reassembly

Repair Procedures: Inspection: 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 piston and 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.
      3. Fig 1: Identifying Piston Front Mark And Rod
      G04803628Courtesy of HYUNDAI MOTOR CO.
  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.
    3. Fig 2: Identifying Piston Rings Gap Direction
    G05347931Courtesy of HYUNDAI MOTOR CO.
  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).
    4. Fig 3: Identifying Bearings And Rod Cap
    G04803630Courtesy of HYUNDAI MOTOR CO.
  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).
      2. Fig 4: Locating Upper Bearings
      G05347933Courtesy of HYUNDAI MOTOR CO.
    2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
  5. Install thrust bearings.

    Install the 2 thrust bearings(A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

    6. Fig 5: Identifying Thrust Bearings
    G04879607Courtesy of HYUNDAI MOTOR CO.
  6. Place crankshaft on the cylinder block.
    7. Fig 6: Identifying Crankshaft
    G04879583Courtesy of HYUNDAI MOTOR CO.
  7. Place main bearing caps on cylinder block.
  8. Install main bearing cap bolts.
    1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.

      Tightening torque 

      Main bearing cap bolt

      49.0Nm (5.0 kgf.m, 36.2lb-ft) + 90° (No. 1 ~ 8)

      19.6 Nm (2.0 kgf.m, 14.46lb-ft)+ 120° (No. 9 ~ 16)

      29.4 ~ 31.4Nm (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1lb-ft) (No. 17 ~ 22)

      NOTE:
      • Always use new main bearing cap bolts.
      • If any of the bearing cap bolts are broken or deformed, replace it.
      Fig 7: Identifying Bearing Cap Bolts Tightening
      G06105239Courtesy of HYUNDAI MOTOR CO.

      Use SST(09221-4A000), install main bearing cap bolts.

      Fig 8: Tightening Main Bearing Cap Bolts
      G05347937Courtesy of HYUNDAI MOTOR CO.
    2. Check that the crankshaft turns smoothly.
  9. Check crankshaft end play.
  10. Install 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.

      4. 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 9: Tightening Connecting Rod Bearing Cap Bolts
      G05347938Courtesy of HYUNDAI MOTOR CO.
    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 10: Inserting Piston In Cylinder Bore
      G05347939Courtesy of HYUNDAI MOTOR CO.
  11. Check the connecting rod end play.
  12. Install the oil drain cover (A).

    Tightening torque 

    8.8 ~ 10.8Nm (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)

    Fig 11: Locating Oil Drain Cover
    G05347940Courtesy of HYUNDAI MOTOR CO.
    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 12: Identifying Sealant Area On Oil Drain Cover
    G04883097Courtesy of HYUNDAI MOTOR CO.
  13. Install the rear oil seal case (A).

    Tightening torque 

    9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

    Fig 13: Locating Rear Oil Seal Case
    G05347942Courtesy of HYUNDAI MOTOR CO.
    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 14: Applying Sealant To Inner Threads Of Bolt Holes
      G05347943Courtesy of HYUNDAI MOTOR CO.
  14. Using SST(09231-3C200, 09231-H1100), install rear oil seal.
    15. Fig 15: Identifying SST (09231-3C200, 09231-H1100) On Rear Oil Seal
    G04879617Courtesy of HYUNDAI MOTOR CO.
  15. Install the baffle plate (A).

    Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.

    Tightening torque 

    9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

    Fig 16: Baffle Plate Bolts Tightening Sequence
    G06105269Courtesy of HYUNDAI MOTOR CO.
  16. Install the upper oil pan.

    A. Using a gasket scraper, remove all the old gasket 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 17: Identifying Area Applying Liquid Sealant To Upper Oil Pan
    G04879619Courtesy of HYUNDAI MOTOR CO.
    NOTE:
    • Clean the sealing face before assembling two parts.
    • Remove harmful foreign materials on the sealing face before 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 

    9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

    Fig 18: Upper Oil Pan Bolts Tightening Sequence
    G05347946Courtesy of HYUNDAI MOTOR CO.
  17. Install the knock sensors (A).

    Tightening torque 

    15.7 ~ 23.5Nm (1.6 ~ 2.4kgf.m, 11.6 ~ 17.3lb-ft)

    Fig 19: Identifying Knock Sensor With Bolts
    G06801614Courtesy of HYUNDAI MOTOR CO.
  18. Install the drive plate (A) with adapter plate (B).

    Tightening torque 

    71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~ 55.69lb-ft)

    Fig 20: Identifying Drive Plate (A) And Adapter Plate (B)
    G06105224Courtesy of HYUNDAI MOTOR CO.
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