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Repair Procedures: Disassembly

Engine removal is required for this procedure.

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  • 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 misconception.
  • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
  1. Remove the engine assembly from the vehicle. (Refer to ENGINE AND TRANSAXLE ASSEMBLY in this group)
  2. Attach the engine to engine stand for disassembly.
  3. Remove the intake manifold and exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM in this group)
  4. Remove the cylinder head. (Refer to CYLINDER HEAD in this group)
  5. Remove the timing chain. (Refer to TIMING SYSTEM in this group)
  6. Remove the engine coolant temperature control assembly. (Refer to COOLING SYSTEM in this group)
  7. Remove the oil pump. (Refer to LUBRICATION SYSTEM in this group)
  8. Remove the adapter plate (A) and the drive plate (B).
    Fig 1: Identifying Adapter Plate And Drive Plate
    G07308833Courtesy of HYUNDAI MOTOR CO.
  9. Remove the crankshaft adapter (A).
    Fig 2: Identifying Crankshaft Adapter
    G07308834Courtesy of HYUNDAI MOTOR CO.
  10. Remove the cylinder block rear cover (A).
    Fig 3: Identifying Cylinder Block Rear Cover
    G07308835Courtesy of HYUNDAI MOTOR CO.
  11. Remove the separator (A) and the water jacket inserts (B).
    Fig 4: Identifying Separator And Water Jacket Inserts
    G07308836Courtesy of HYUNDAI MOTOR CO.
    Fig 5: Identifying Separator And Water Jacket Inserts
    G07308837Courtesy of HYUNDAI MOTOR CO.
  12. Remove the cylinder block bank cover (A) and the gasket (B).
    Fig 6: Identifying Cylinder Block Bank Cover And Gasket
    G07308838Courtesy of HYUNDAI MOTOR CO.
  13. Check the connecting rod end play.
  14. Check the connecting rod cap oil clearance.
  15. Remove the piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod cap (A).
      Fig 7: Identifying Connecting Rod Cap
      G07308839Courtesy of HYUNDAI MOTOR CO.
    3. 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.
  16. Check the main bearing oil clearance.
  17. Check the crankshaft end play.
  18. Remove the lower crankcase assembly (A).
    Fig 8: Identifying Lower Crankcase Assembly
    G07308840Courtesy of HYUNDAI MOTOR CO.
  19. Lift the crankshaft (A) out of engine, being careful not to damage journals.
    Fig 9: Identifying Crankshaft
    G07308841Courtesy of HYUNDAI MOTOR CO.
    NOTE: Arrange the main bearings and center bearings in the correct order.
  20. 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.

  21. Remove the piston rings.
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove 2 side rails and the oil ring spacer by hand.
      NOTE: Arrange the piston rings in the correct order only.
  22. Disconnect connecting rod from piston.
    1. Remove the snap rings from piston.
    2. Remove the piston pin.
    3. Remove the connecting rod and the piston.
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