Repair procedures: Reassembly

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 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 in illustration.
   Fig 2: Positioning Piston Rings

   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 (A) in the connecting rod and connecting rod cap (B).
   Fig 3: Identifying Connecting Rod Bearings And Connecting Rod Cap

   Courtesy of HYUNDAI MOTOR CO.

1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A).
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.

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

Fig 4: Identifying Thrust Bearings

Courtesy of HYUNDAI MOTOR CO.

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 in illustration.

   Tightening torque 

   27.5 ~ 31.4 Nm (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft) + 60 ~ 64°

   Fig 5: Identifying Bearing Cap Bolts Tightening Sequence

   Courtesy of HYUNDAI MOTOR CO.
3. Retighten the bearing cap bolts by 60°~66° in the numerical order shown in illustration.

   Tightening torque 

   Main bearing cap bolt:

   27.5 ~ 31.4 Nm (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft) + 60 ~ 64°

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 nuts : 49.0 ~ 52.0 Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)
   NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
   Fig 6: Installing Ring Compressor

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

9.8 ~ 11.8 Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Fig 7: Identifying Rear Oil Seal Case And Bolts

Courtesy of HYUNDAI MOTOR CO.

1. Apply engine oil to a new oil seal lip.
2. Using SST (09231-23200, 09231-H1100) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
   Fig 8: Installing Rear Oil Seal

   Courtesy of HYUNDAI MOTOR CO.

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

Tightening torque 

14.7 ~ 21.6 Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

Fig 9: Identifying Oil Screen, Gasket And Bolts

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. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Use liquid gasket 'TB 1217H' 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 with the 19 bolts.

   Uniformly tighten the bolts in several passes.

   Tightening torque 

   9.8 ~ 11.8 Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

1. Apply adhesive to 2 or 3 threads.

   Adhesive : Three bond 2310/2350 or equivalent.

2. Install the oil pressure sensor (A).

   Tightening torque 

   14.7 ~ 21.6 Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

   Fig 10: Identifying Oil Pressure Sensor

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

16.7 ~ 26.5 Nm (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft)

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 

   18.6 ~ 23.5 Nm (1.9~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

   Fig 11: Identifying Oil Level Gauge Assembly

   Courtesy of HYUNDAI MOTOR CO.

Tightening torque 

117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)

Tightening torque 

117.7 ~ 127.5Nm (12.0 ~ 13.0kgf.m, 86.8 ~ 94.0lb-ft)