Repair Procedures: Disassembly

Information 

• Mark all wiring connector and hoses to avoid misconnection.
• To release the fuel system pressure before removing the engine assembly, start the engine without fuel pump relay. Then, switch "OFF" the ignition when engine stops.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Remove the engine and transaxle assembly.

   (Refer to Engine and Transaxle Assembly - "REPAIR PROCEDURES ")

2. Remove the harness clamp from the wiring connector around the engine and transaxle and remove the connector bracket.

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   Courtesy of HYUNDAI MOTOR AMERICA

3. Remove the transaxle assembly from the engine assembly.

   Intelligent variable transmission (IVT)

   (Refer to Intelligent Variable Transmission (IVT) System - "REPAIR PROCEDURES ")

   Manual transaxle

   (Refer to Manual Transaxle System - "REPAIR PROCEDURES ")

4. Intelligent variable transmission (IVT): Remove the drive plate.

   (Refer to "DRIVE PLATE ")

   Manual transaxle: Remove the flywheel.

   (Refer to "FLYWHEEL ")

5. Remove the rear oil seal.

   (Refer to "REAR OIL SEAL ")

6. Install the engine assembly to engine stand for disassembly.
7. Remove the oil pan.

   (Refer to Lubrication System - "OIL PAN ")

8. Remove the timing chain.

   (Refer to Timing System - "TIMING CHAIN ")

9. Remove the intake manifold.

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

10. Remove the exhaust manifold.

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

11. Remove the electric EGR control valve.

    (Refer to Engine Control/Fuel System - "ELECTRIC EGR CONTROL VALVE ")

12. Remove the EGR cooler.

    (Refer to Intake and Exhaust System - "EGR COOLER ")

13. Remove the oil filter body.

    (Refer to Lubrication System - "OIL FILTER BODY ")

14. Remove the oil pump.

    (Refer to Lubrication System - "OIL PUMP ")

15. Remove the cylinder head.

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

16. Remove the piston and connecting rod assembly.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod bearing caps (A).

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       Information 

       • Mark the connecting rod, and caps to be able to reassemble in the original position and direction.
    3. Push the piston and connecting rod assembly (A) with upper bearing through the top of the cylinder block.

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    NOTE:

    • Keep the connecting rod and cap with their bearings assembled together.
    • Arrange the piston and connecting rod assemblies in the correct order.
17. 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 the piston and piston pin as a set.

18. Disassemble the piston rings.
    1. Using a piston ring expender, remove the 2 piston rings (A).
    2. Remove the oil ring (B) by hand.
19. Disassemble the connecting rod from the piston.
    1. Remove the snap ring (C) from the piston.
    2. Using a press, remove the piston pin (D) from the piston.
    3. Disassemble the piston (E) and connecting rod (F).

    Courtesy of HYUNDAI MOTOR AMERICA