Repair procedures: Reassembly

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 1: Identifying Piston Front Mark And Connecting Rod Front Mark

   Courtesy of HYUNDAI MOTOR CO.

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 illustration.
   Fig 2: Installing Piston Rings

   Courtesy of HYUNDAI MOTOR CO.

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: Identifying Bearings And Connecting Rod Cap

   Courtesy of HYUNDAI MOTOR CO.

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

   Courtesy 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.

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

Fig 5: Identifying Thrust Bearings

Courtesy of HYUNDAI MOTOR CO.

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

   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 7: Identifying Main Bearing Cap Bolts Tightening Sequence

     Courtesy of HYUNDAI MOTOR CO.

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

   Fig 8: Installing Main Bearing Cap Bolts Using SST (09221-4A000)

   Courtesy of HYUNDAI MOTOR CO.
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 

   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: Installing Connecting Rod Bearing Cap Bolts Using SST (09221-4A000)

   Courtesy 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: Installing Piston Rings

     Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)

Fig 11: Identifying Oil Drain Cover With Bolts

Courtesy of HYUNDAI MOTOR CO.

Fig 12: Identifying Liquid Sealant Applying Area On Oil Drain Cover

Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)

Fig 13: Identifying Rear Oil Seal Case With Bolts

Courtesy of HYUNDAI MOTOR CO.

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

Tightening torque 

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 16: Identifying Baffle Plate Bolts In Tightening Sequence

Courtesy of HYUNDAI MOTOR CO.

1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. 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 Liquid Sealant Applying Area On Upper Oil Pan

   Courtesy 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.
3. Install 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 18: Identifying Upper Oil Pan Bolts In Tightening Sequence

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~ 17.36lb-ft)

Fig 19: Identifying Knock Sensor With Bolts

Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

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