Repair Procedures: Reassembly

1. Install the snap ring in one side of the piston pin hole.
2. Align the piston front mark and the connecting rod front mark.
   Fig 1: Identifying Piston And Connecting Rod Front Mark

   Courtesy of HYUNDAI MOTOR CO.
3. Insert the piston pin into the piston pin hole and the small end bore of connecting rod.
4. Install the snap ring in the other side after inserting the piston pin.
   NOTE: Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.

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.
   Fig 2: Identifying Piston Installing Direction

   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 5 upper bearings.
   Fig 4: Identifying Main Bearings And Center Bearings

   Courtesy of HYUNDAI MOTOR CO.
2. Align the bearing claw with the claw groove of the lower crankcase and push in the 5 lower bearings.

Fig 5: Identifying Main Bearings And Center Bearings

Courtesy of HYUNDAI MOTOR CO.

1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Install the O-ring (A) to cylinder block.
3. Before assembling the lower crankcase assembly, the liquid sealant LT 5900H or equivalent should be applied on cylinder block bottom.

   The part must be assembled within 5 minutes after the sealant was applied.

   Bead width:  2.5mm(0.1in)

   Fig 7: Identifying Cylinder Block O-Ring

   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 cylinder block.
   • To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
4. Install the lower crankcase assembly.

1. Install and uniformly tighten the lower crankcase assembly bolts, in several passes, in the sequence shown.

   Tightening torque 

   Main bearing cap bolts (1~20)

   37.3~41.2 N.m (3.8~4.2 kgf.m, 27.5~30.4 lb-ft) + 120°

   Flange bolts (21~35)

   21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

   NOTE:

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

   Courtesy of HYUNDAI MOTOR CO.

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

   Fig 9: Installing Bearing Cap Bolts Using SST(09221-4A000)

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

Fig 10: Identifying Piston And Connecting Rod Front Mark

Courtesy of HYUNDAI MOTOR CO.

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: 

   22.6~26.5N.m (2.3~2.7kgf.m, 16.6~19.5lb-ft) + 98°~102°

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

   Fig 11: Checking Connecting Rod Bearing Oil Clearance

   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 12: Checking Connecting Rod End Play

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque: 

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

Fig 13: Identifying Cylinder Block Rear Cover

Courtesy of HYUNDAI MOTOR CO.

At this time, the depth of the oil seal (A) from the cylinder block surface is 1mm(0.039in).

Fig 15: Identifying Oil Seal, Special Tool And Plastic Hammer

Courtesy of HYUNDAI MOTOR CO.

Fig 16: Identifying Oil Seal Depth From Cylinder Block Surface

Courtesy of HYUNDAI MOTOR CO.

Tightening torque: 

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

Fig 17: Identifying Cylinder Block Bank Cover And New Gasket

Courtesy of HYUNDAI MOTOR CO.

Tightening torque: 

98.1~107.9N.m(10.0~11.0kgf.m,72.3~79.6lb-ft)

Fig 20: Identifying Adapter Plate And Drive Plate

Courtesy of HYUNDAI MOTOR CO.