Repair Procedures: Reassembly

1. Install the piston pin with snap ring 2EA and check the snap ring assembly thoroughly.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.

Fig 1: Locating Piston Front Mark And Connecting Rod Front Mark

Courtesy of HYUNDAI MOTOR AMERICA

1. Install the coil spring and oil ring 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.

Fig 2: Positioning Piston Ring Ends

Courtesy of HYUNDAI MOTOR AMERICA

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 3: Installing Bearings In Connecting Rod And Connecting Rod Cap

Courtesy of HYUNDAI MOTOR AMERICA

Tightening torque: 

27.5 ~ 31.3 N.m (2.8 ~ 3.2 kgf.m, 20.2 ~ 23.1 lb-ft)

Fig 4: Installing Oil Jets

Courtesy of HYUNDAI MOTOR AMERICA

1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A).
   Fig 5: Pushing Upper Bearings

   Courtesy of HYUNDAI MOTOR AMERICA
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

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

Fig 6: Installing Thrust Bearings Under No. 3 Journal Position Of Cylinder Block With Oil Grooves Facing Outward

Courtesy of HYUNDAI MOTOR AMERICA

1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.

   Tightening torque 

   Main bearing cap bolt

   49.0 N.m (5.0 kgf.m, 36.2 lb-ft) + 90° (1 ~ 8)

   19.6 N.m (2.0 kgf.m, 14.5 lb-ft) + 120° (9 ~ 16)

   29.4 ~ 31.4 N.m (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft) (17 ~ 24)

   NOTE:

   • Always use new main bearing cap bolts.
   • If any of the bearing cap bolts are broken or deformed, replace it.
   Fig 8: Main Bearing Cap Bolts Tightening Sequence

   Courtesy of HYUNDAI MOTOR AMERICA

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

   Fig 9: Installing Main Bearing Cap Bolts

   Courtesy of HYUNDAI MOTOR AMERICA
2. Check that the crankshaft turns smoothly.

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: 

   27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft) + (68 ~ 72°)

   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: Installing Ring Compressor

   Courtesy of HYUNDAI MOTOR AMERICA
   NOTE: Use SST (09221-4A000), install connecting rod bearing cap bolts.
   Fig 11: Installing Connecting Rod Bearing Cap Bolts

   Courtesy of HYUNDAI MOTOR AMERICA

Tightening torque: 

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

Fig 12: Installing Oil Drain Cover With Gasket

Courtesy of HYUNDAI MOTOR AMERICA

Tightening torque: 

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

Fig 13: Installing Rear Oil Seal Case

Courtesy of HYUNDAI MOTOR AMERICA

Fig 14: Applying Sealant To Inner Threads Of Bolt Holes

Courtesy of HYUNDAI MOTOR AMERICA

(Refer to Cylinder Block - "Rear Oil Seal ")

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

Tightening torque: 

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

Fig 15: Baffle Plate Bolts Tightening Sequence

Courtesy of HYUNDAI MOTOR AMERICA

(Refer to Lubrication System - "OIL PAN ")

Tightening torque: 

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

Fig 16: Installing Oil Cover And Gasket

Courtesy of HYUNDAI MOTOR AMERICA

Tightening torque: 

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

Fig 17: Installing Knock Sensor

Courtesy of HYUNDAI MOTOR AMERICA

(Refer to Cylinder Block - "Drive Plate ")

(Refer to Lubrication System - "OIL FILTER ")

(Refer to Lubrication System - "OIL PUMP ")

(Refer to Cylinder Block - "Water Jacket Separator ")

(Refer to Cylinder Head Assembly - "CYLINDER HEAD ")

(Refer to Engine Mechanical System - "WATER TEMPERATURE CONTROL ASSEMBLY ")

(Refer to Timing System - "TIMING CHAIN ")

(Refer to Intake And Exhaust System - "EXHAUST MANIFOLD ")

(Refer to Intake And Exhaust System - "INTAKE MANIFOLD ")

(Refer to Engine And Transmission Assembly - "ENGINE AND TRANSMISSION ASSEMBLY ")