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Home >> Hyundai >> 2004 >> Elantra GLS, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.0L 4-Cylinder Engine >> Engine Block >> Reassembly

Engine Block: Reassembly

NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  • Replace all gaskets, O-rings and oil seals with new parts.
  1. Assemble piston and connecting rod.
    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 & Connecting Rod Alignment Marks
      G00747566Courtesy of HYUNDAI MOTOR CO.
  2. Install piston rings.
    1. Install the oil ring expander 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: Locating Piston Ring Ends
      G00747567Courtesy of HYUNDAI MOTOR CO.
  3. Install connecting rod bearings.
    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: Installing Connecting Rod Bearings
      G00747568Courtesy of HYUNDAI MOTOR CO.
  4. Install main bearings.
    NOTE: Upper 1,2,4,5 bearings have an oil groove of oil holes; Lower bearings do not.
    1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A).
      Fig 4: Installing Crankshaft Main Bearings
      G00747569Courtesy 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.
  5. Install thrust 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: Installing Crankshaft Thrust Bearings
    G00747570Courtesy of HYUNDAI MOTOR CO.
  6. Place crankshaft on the cylinder block.
  7. Place main bearing caps on cylinder block.
  8. Install main bearing cap bolts.
    NOTE:
    • The main bearing cap bolts are tightened in 2 progressive steps.
    • If any of the bearing cap bolts in broken or deformed, replace it.
    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: 30Nm (300kgf.cm, 22lbf.ft) 

      Fig 6: Installing Crankshaft Main Bearing Caps
      G00747571Courtesy of HYUNDAI MOTOR CO.
    3. Retighten the bearing cap bolts by 60°~65° in the numerical order shown.

      Tightening torque 

      1. Main bearing cap bolt:
      2. 30Nm (300kgf.cm, 22lbf.ft) + 60° ~ 65°
    4. Check that the crankshaft turns smoothly.
  9. Check crankshaft end play. See Figure.
  10. Install piston and connecting rod assemblies.
    NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
    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 nuts : 50 ~ 53Nm (500 ~ 530kgf.cm, 36.9 ~ 39lbf.ft)
    NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
    Fig 7: Installing Piston & Rod Assembly
    G00747572Courtesy of HYUNDAI MOTOR CO.
  11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).

    Tightening torque 

    1. 10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
      Fig 8: Installing Rear Oil Seal Case
      G00747573Courtesy of HYUNDAI MOTOR CO.
    NOTE: Check that the mating surfaces are clean and dry.
  12. Install rear oil seal.
    1. Apply engine oil to a new oil seal lip.
    2. Using SST (09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
      Fig 9: Installing Rear Oil Seal
      G00747574Courtesy of HYUNDAI MOTOR CO.
  13. Install front case. See Figure.
  14. Install oil screen.

    Install a new gasket (B) and oil screen (A) with 2 bolts (C).

    Tightening torque 

    1. 15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
      Fig 10: Installing Oil Screen
      G00747575Courtesy of HYUNDAI MOTOR CO.
  15. Install oil pan.
    1. Using a razor blade and gasket scraper, remove all the old packing 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 MS 721-40A or equivalent.

      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) with the 19 bolts.

      Uniformly tighten the bolts in several passes.

      Tightening torque 

      1. 10 ~ 12Nm (100 ~ 120kgf.cm, 7.3 ~ 8.8lbf.ft)
        Fig 11: Installing Oil Pan
        G00747576Courtesy of HYUNDAI MOTOR CO.
    4. Install water pump. See Water Pump .
    5. Install oil pressure sensor.
      1. Apply adhesive to 2 or 3 threads.

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

      2. Install the oil pressure sensor (A).

      Tightening torque 

      1. 15 ~ 22Nm (150 ~ 220kgf.cm, 11 ~ 16lbf.ft)
        Fig 12: Installing Oil Pressure Sensor
        G00747577Courtesy of HYUNDAI MOTOR CO.
    6. Install knock sensor (A).

      Tightening torque 

      1. 17 ~ 27Nm (170 ~ 270kgf.cm, 12.5 ~ 20lbf.ft)
        Fig 13: Installing Knock Sensor
        G00747578Courtesy of HYUNDAI MOTOR CO.
    7. Install oil level gauge assembly.
      1. Install a new O-ring on the oil level gauge.
      2. Apply engine oil on the O-ring.
      3. Install the oil level gauge assembly (A) with the bolt.

      Tightening torque 

      1. 12 ~ 15Nm (120 ~ 150kgf.cm, 9 ~ 11lbf.ft)
        Fig 14: Installing Oil Level Gauge Assembly
        G00747579Courtesy of HYUNDAI MOTOR CO.
    8. Install cylinder head. See INSTALLATION  under CYLINDER HEAD ASSEMBLY.
    9. Install timing belt. See INSTALLATION  under TIMING SYSTEM.
    10. Remove engine stand.
    11. A/T : Install drive plate.

      Tightening torque 

      1. 120 ~ 130Nm (1200 ~ 1300kgf.cm, 89 ~ 96lbf.ft)
    12. M/T : Install flywheel.

      Tightening torque 

      1. 120 ~ 130Nm (1200 ~ 1300kgf.cm, 89 ~ 96lbf.ft)
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