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Home >> Hyundai >> 2005 >> Tucson GL, 4WD, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> Engine (G4GC-GSL 2.0L) >> Engine Block >> Disassembly

Engine Block: Disassembly

  1. M/T: remove flywheel.
  2. A/T: remove drive plate.
  3. Install engine to engine stand for disassembly.
  4. Remove timing belt. (See REMOVAL )
  5. Remove cylinder head. (See REMOVAL )
  6. Remove oil level gauge assembly (A).
    Fig 1: Identifying Oil Level Gauge Assembly
    G03761948Courtesy of HYUNDAI MOTOR CO.
  7. Remove knock sensor (A).
    Fig 2: Identifying Knock Sensor
    G03761949Courtesy of HYUNDAI MOTOR CO.
  8. Remove oil pressure sensor (A).
    Fig 3: Identifying Oil Pressure Sensor
    G03761950Courtesy of HYUNDAI MOTOR CO.
  9. Remove water pump. (See WATER PUMP )
  10. Remove oil pan (A).
    Fig 4: Identifying Oil Pan
    G03761951Courtesy of HYUNDAI MOTOR CO.
  11. Remove oil screen.

    Remove the 2 bolts (C), oil screen (A) and gasket (B).

    Fig 5: Removing Bolts, Oil Screen And Gasket
    G03761952Courtesy of HYUNDAI MOTOR CO.
  12. Check the connecting rod end play. (See CONNECTING ROD AND CRANKSHAFT )
  13. Remove the connecting rod caps and check oil clearance. (See CONNECTING RODS )
  14. Remove piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. 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.
  15. Remove front case. (See REMOVAL )
  16. Remove rear oil seal case.

    Remove the 5 bolts (B) and rear oil seal case (A).

    Fig 6: Removing Bolts And Rear Oil Seal Case
    G03761953Courtesy of HYUNDAI MOTOR CO.
  17. Remove crankshaft bearing cap and check oil clearance. (See CONNECTING ROD AND CRANKSHAFT )
  18. Check the crankshaft end play. (See WATER PUMP )
  19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    NOTE: Arrange the main bearings and thrust bearings in the correct order.
    Fig 7: Lifting Crankshaft
    G03761954Courtesy of HYUNDAI MOTOR CO.
  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 the piston and pin as a set.

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