Repair procedures: Disassembly

M/T : remove flywheel.
A/T : remove drive plate.
Install engine to engine stand for disassembly.
Remove timing belt.
Remove cylinder head.
Remove oil level gauge assembly (A).

Fig 1: Identifying Oil Level Gauge Assembly
Courtesy of HYUNDAI MOTOR CO.
Remove knock sensor.
Remove oil pressure sensor (A).

Fig 2: Identifying Oil Pressure Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove water pump.
Remove oil pan.
Remove oil screen.
Remove the 2 bolts (C), oil screen (A) and gasket (B).

Fig 3: Identifying Oil Screen, Bolts And Gasket
Courtesy of HYUNDAI MOTOR CO.
Check the connecting rod end play.
Remove the connecting rod caps and check oil clearance.
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.
Remove front case.
Remove rear oil seal case.
Remove the 5 bolts (B) and rear oil seal case (A).

Fig 4: Identifying Rear Oil Seal Case And Bolts
Courtesy of HYUNDAI MOTOR CO.
Remove crankshaft bearing cap and check oil clearance.
Check the crankshaft end play.
Lift the crankshaft (A) out of the engine, being careful not to damage journals.
NOTE: Arrange the main bearings and trust washers in the correct order.

Fig 5: Identifying Crankshaft
Courtesy of HYUNDAI MOTOR CO.
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.
Remove piston rings.
1. Using a piston ring expender, remove the 2 compression rings.
2. Remove the 2 side rails and oil ring by hand.
  NOTE: Arrange the piston rings in the correct order only.
Disconnect connecting rod from piston.