Engine Block: Reassembly

1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.
   Fig 1: Identifying Piston Front Mark & Connecting Rod Front Mark

   Courtesy of HYUNDAI MOTOR CO.

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: Positioning Piston Ring End Gaps

   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 in the connecting rod and connecting rod cap.
   Fig 3: Installing Connecting Rod Bearings

   Courtesy of HYUNDAI MOTOR CO.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 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 (A), and push in the 4 lower bearings (B).
   Fig 5: Identifying Main Bearing Cap & Lower Bearing

   Courtesy of HYUNDAI MOTOR CO.

Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

Fig 6: Identifying Thrust Bearing

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Tightening torque 

Main bearing cap bolt

M8

13 ~ 19 Nm (130 ~ 190 kgf.cm, 10 ~ 14 lbf.ft) + 90° ~ 94°

M10

27 ~ 33 Nm (270 ~ 330 kgf.cm, 19.5 ~ 24 lbf.ft) + 90° ~ 94°

1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
2. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

   Tightening torque 

   M8 (A): 13 ~ 19 Nm (130 ~ 190 kgf.cm, 10 ~ 14 lbf.ft)

   M10 (B): 27 ~ 33 Nm (270 ~ 330 kgf.cm, 19.5 ~ 24 lbf.ft)

   Fig 8: Installing Main Bearing Cap Bolts

   Courtesy of HYUNDAI MOTOR CO.
3. Retighten the bearing cap bolts by 90° ~ 94° in the numerical order shown.
   Fig 9: Identifying Main Bearing Cap Bolts Tightening Sequence

   Courtesy of HYUNDAI MOTOR CO.
4. 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 

   16 ~ 20 Nm (160 ~ 200 kgf.cm, 12 ~ 15 lbf.ft) + 90° ~ 94°

   NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
   Fig 10: Installing Piston And Connecting Rod Assemblies

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

10 ~ 12 Nm (100 ~ 120 kgf.cm, 7.3 ~ 8.8 lbf.ft)

Fig 11: Identifying Oil Seal Case

Courtesy of HYUNDAI MOTOR CO.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231 - 33000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
   Fig 12: Tapping In Rear Oil Seal

   Courtesy of HYUNDAI MOTOR CO.

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. Install the oil pan (A) with the 17 bolts.

   Uniformly tighten the bolts in several passes.

   Tightening torque 

   19 ~ 28 Nm (190 ~ 280 kgf.cm, 14 ~ 20 lbf.ft): (1 ~ 15)

   5 ~ 7 Nm (50 ~ 70 kgf.cm, 4 ~ 5 lbf.ft): (16,17)

   Fig 13: Identifying Oil Pan

   Courtesy of HYUNDAI MOTOR CO.
   Fig 14: Oil Pan Bolts Installation Sequence

   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.

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

Tightening torque 

15 ~ 22 Nm (150 ~ 220 kgf.cm, 11 ~ 16 lbf.ft)

Fig 15: View Of Oil Screen & Bolts

Courtesy of HYUNDAI MOTOR CO.

1. 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.
2. Install the lower oil pan 10 bolts.

   Uniformly tighten the bolts several passes

   Tightening torque 

   10 ~12 Nm (100 ~ 120 kgf.cm, 7.3 ~ 8.8 lbf.ft)

   Fig 16: Lower Oil Pan Bolt Installation Sequence

   Courtesy of HYUNDAI MOTOR CO.

1. Apply adhesive to 2 or 3 threads. Adhesive: THREE BOND TB2403 or equivalent.
2. Install the oil pressure sensor (A).

   Tightening torque 

   15 ~ 22 Nm (150 ~ 220 kgf.cm, 11 ~ 16 lbf.ft)

   Fig 17: Identifying Oil Pressure Sensor

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

17 ~ 26 Nm (170 ~ 260 kgf.cm, 12.5 ~ 19 lbf.ft)

Fig 18: Identifying Knock Sensors

Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

35 ~ 55 Nm (350 ~ 550 kgf.cm, 25.8 ~ 40.6 lbf.ft)

Fig 19: Identifying Power Steering Pump Bracket

Courtesy of HYUNDAI MOTOR CO.

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 

   12 ~ 15 Nm (120 ~ 150 kgf.cm, 9 ~ 11 lbf.ft)

Tightening torque 

73 ~ 77 Nm (730 ~ 770 kgf.cm, 53 ~ 56 lbf.ft)