Repair Procedures: Reassembly

1. Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
   CAUTION:

   • Take care that piston pin is not to be damaged during pressing process.
   • When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.

   Piston pin outer DIA.: 

   21.001 ~ 21.006 mm (0.8268 ~ 0.8270 in)

   Connecting rod small end inner DIA.: 

   20.974 ~ 20.985 mm (0.8257 ~ 0.8261 in)

   Interference: 

   -0.032 ~ -0.016 mm (-0.0013 ~ -0.0006 in.)

2. Use a hydraulic press for installation.
3. 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.
   Fig 2: Position For 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 5 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 5 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. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.

   Tightening torque 

   14.7 Nm (1.5 kgf.m, 10.8 lb-ft) + 27.5~31.4 Nm (2.8~3.2 kgf.m, 20.3~23.1 lb-ft) + 120~125°

   Fig 7: Identifying Bearing Cap Bolts Tightening Sequence

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

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
2. 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.
3. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

   Tightening torque 

   17.7 ~ 21.6 Nm (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°

   CAUTION: Always use new connecting rod cap bolts.
   NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
   Fig 8: Installing Rod Caps With Bearings

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

Step 1: 8.8 ~ 9.8 N.m (0.9 ~ 1.0 kgf.m, 6.5 ~ 7.2 lb-ft)

Step 2: 17.7 ~ 20.6 N.m (1.8 ~ 2.1 kgf.m, 3.0 ~ 15.2 lb-ft)

Step 3: 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)

Fig 10: Identifying Ladder Frame

Courtesy of HYUNDAI MOTOR CO.

Fig 11: Identifying Ladder Frame Bolts Tightening Sequence

Courtesy of HYUNDAI MOTOR CO.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231-H1100, 09214-3K100) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.

Tightening torque 

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

Fig 12: Identifying CKP Sensor

Courtesy of HYUNDAI MOTOR CO.

1. Apply adhesive to 2 or 3 threads.

   Adhesive: MS 721-39 (B) or equivalent.

2. Install the oil pressure sensor (A).

   Tightening torque 

   7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

   Fig 13: Identifying Oil Pressure Sensor

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

Fig 14: Identifying Knock Sensor

Courtesy of HYUNDAI MOTOR CO.

1. Install a new O-ring on the oil dip stick.
2. Apply engine oil on the O-ring.
3. Install the oil dip stick (A) with the bolt.

   Tightening torque 

   7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

   Fig 15: Identifying Oil Dip Stick

   Courtesy of HYUNDAI MOTOR CO.

1. Using a razor blade and gasket scraper, remove all the old gasket material from the gasket surfaces.
   NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket.
2. Apply liquid gasket as an even bead, centered between the edges of the mating surface.

   Use liquid gasket LOCTITE5900H or THREEBOND 1217H or equivalent (MS721-40).

   Bead width:  3.0 mm (0.12 in)

   Fig 16: Identifying Liquid Gasket

   Courtesy of HYUNDAI MOTOR CO.
   NOTE:

   • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
   • Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
   • After assembly, wait at least 30 minutes before filling the engine with oil.
3. Install the oil pan (A).

   Uniformly tighten the bolts in several passes.

   Tightening torque 

   M9 (B): 30.4 ~ 34.3 N.m (3.1 ~ 3.5 kgf.m, 22.4 ~ 25.3 lb-ft)

   M6 (C): 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   Fig 17: Identifying Oil Pan With Bolts

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

117.7 ~ 127.5 N.m (12 ~ 13 kgf.m, 86.8 ~ 94.0 lb-ft)

M/T: Install flywheel (B).

Tightening torque 

117.7 ~ 127.5 N.m (12 ~ 13 kgf.m, 86.8 ~ 94.0 lb-ft)

Fig 18: Identifying Drive Plate And Flywheel With Bolts

Courtesy of HYUNDAI MOTOR CO.