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Home >> Hyundai >> 2011 >> Elantra GLS, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Cylinder Block >> Cylinder Block >> Repair Procedures >> Reassembly

Repair Procedures: Reassembly

NOTE:
  • Thoroughly clean all parts to be 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 the piston and the connecting rod.
    1. Install the snap ring (A) in one side of the piston pin hole.
    2. Align the piston front mark and the connecting rod front mark.
    3. Insert the piston pin (B) into the piston pin hole and the small end bore of connecting rod.
    4. Install the snap ring (C) in the other side after inserting the piston pin.
    Fig 1: Identifying Snap Ring
    G07263796Courtesy of HYUNDAI MOTOR CO.
    NOTE: Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.
    CAUTION:
    • Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.
    • Set the snap ring firmly so that the snap ring can contact with the whole groove of the piston pin hole.
  2. Install the piston rings.
    1. Install the oil ring spacer and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the maker mark facing upward.
    3. Position the piston rings so that the ring ends are as shown. (The No. 1 ring should be on the opposite side of the No. 2 ring.)

    Example)

    Fig 2: Positioning Piston Ring
    G07263797Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Check to ensure that the oil ring can be turned smoothly.
  3. Install the 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: Identifying Bearings
    G07263798Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Be careful not to change the position of bearing caps.
  4. Install the crankshaft main bearings.
    NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
    1. Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A).
      Fig 4: Aligning Bearing Claw With Groove Of Cylinder Block
      G07263799Courtesy of HYUNDAI MOTOR CO.
    2. Align the bearing claw with the groove of the lower crankcase (B), and push in the 5 lower bearings (A).
      Fig 5: Aligning Bearing Claw With Groove Of Lower Crankcase
      G07263800Courtesy of HYUNDAI MOTOR CO.
  5. Install the thrust bearings.

    Install the 2 thrust bearings (A) on both sides of the No. 3 journal of the cylinder block with the oil groove facing out.

    Fig 6: Identifying Thrust Bearings
    G07263801Courtesy of HYUNDAI MOTOR CO.
  6. Place the crankshaft (A) on the cylinder block.
    Fig 7: Identifying Crankshaft
    G07263802Courtesy of HYUNDAI MOTOR CO.
  7. Apply liquid sealant on the top surface of the lower crankcase.
    1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
    2. The sealant locations on the lower crankcase and the cylinder block must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
    3. Assemble a new rubber gasket (A) on the top of lower crankcase.
      Fig 8: Identifying Rubber Gasket
      G07263803Courtesy of HYUNDAI MOTOR CO.
    4. Apply liquid sealant on the bottom of the cylinder block. Continuous bead of sealant should be applied to prevent any path from oil leakage.

      Bead width:  2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)

      Sealant:  Threebond 1217H or equivalent

      Fig 9: Identifying Liquid Sealant Apply Area
      G07263804Courtesy of HYUNDAI MOTOR CO.
    CAUTION:
    • Assemble the lower crankcase within 5 minutes after applying sealant.
    • The engine running or pressure test should not be performed within 30 minutes after assembling the lower crankcase.
    • Excess sealant on application surface of sealant of following process should be removed before hardening.
    • If the sealant is applied to the top surface of the lower crankcase, it should be the same position as the cylinder block.
    • To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
  8. Place the lower crankcase on the cylinder block.
  9. Install the main bearing cap bolts.
    Fig 10: Identifying Main Bearing Cap Bolts
    G07263805Courtesy of HYUNDAI MOTOR CO.

    Using SST (09221-4A000), install and tighten the 10 main bearing cap bolts, in several passes, in the sequence as shown.

    Tightening torque 

    1st step:

    27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)

    2nd step: 120 ~ 125°

    Fig 11: Main Bearing Cap Bolts Tightening Sequence
    G07263806Courtesy of HYUNDAI MOTOR CO.
    CAUTION:
    • Do not reuse the bearing cap bolts.
    • Do not apply engine oil on the bolt threads to achieve correct toruqe.
    NOTE:
    • The main bearing cap bolts are tightened in 2 progressive steps.
    • If any of the bearing cap bolts is broken or deformed, replace it.
    • Be sure to assemble the main bearing cap bolts in correct order.
  10. Install the lower crankcase bolts, in several passes, in sequence as shown.

    Tightening torque: 

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

    Fig 12: Lower Crankcase Bolts Tightening Sequence
    G07263807Courtesy of HYUNDAI MOTOR CO.

    Check that the crankshaft turns smoothly.

  11. Check the crankshaft end play.
  12. Install the piston and connecting rod assemblies.
    NOTE:
    • Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
    • Install the piston and connecting rod assembly with the front marks facing the front of the engine.
    1. Install the ring compressor, check that the rings are securely in place, and then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
      Fig 13: Installing Ring Compressor
      G07263808Courtesy of HYUNDAI MOTOR CO.
    2. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
    3. Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.

    Tightening torque 

    1st step:

    17.7 ~ 21.6 Nm (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft)

    2nd step: 88 ~ 92°

    CAUTION: Do not reuse the connecting rod cap bolts.
    NOTE:
    • Using the SST (09221-4A000), tighten the bolts.
    • Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
  13. Check the connecting rod end play.
  14. Install a new rear oil seal.
    1. Apply engine oil to a new oil seal lip.
    2. Using SST (09231-H1100, 09214-2E000) and a hammer, tap in the oil seal (A) until the rear oil seal face is aligned with the cylinder block assembly rear face.
      Fig 14: Identifying Oil Seal
      G07263809Courtesy of HYUNDAI MOTOR CO.
  15. Install the oil screen. (Refer to LUBRICATION SYSTEM in this group)
  16. Install the oil filter. (Refer to LUBRICATION SYSTEM in this group)
  17. Install the CKPS (Crankshaft position sensor) (C).

    Tightening torque: 

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

  18. Install the OPS (Oil pressure switch) (B).

    Tightening torque: 

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

  19. Install the knock sensor (A).

    Tightening torque: 

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

    Fig 15: Identifying Knock Sensor
    G07263810Courtesy of HYUNDAI MOTOR CO.
  20. Install the water inlet fitting and the thermostat assembly. (Refer to COOLING SYSTEM in this group)
  21. Install the water pump assembly. (Refer to COOLING SYSTEM in this group)
  22. Install the A/C compressor. (Refer to INSTALLATION
  23. Install the cylinder head assembly. (Refer to CYLINDER HEAD in this group)
  24. Install the timing chain including the drive belt, the cylinder head cover, the alternator and the timing chain cover. (Refer to TIMING SYSTEM in this group)
  25. Install the intake manifold and exhaust manifold. (Refer to INTAKE AND EXHAUST SYSTEM in this group)
  26. Remove the engine from an engine stand for assembly.
  27. Manual transaxle: Install the flywheel (A).
    Fig 16: Identifying Flywheel
    G07263811Courtesy of HYUNDAI MOTOR CO.

    Automatic transaxle: Install the drive plate (A) and the adapter plate (B).

    Tightening torque: 

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

    Fig 17: Identifying Drive Plate
    G07263812Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Do not reuse the bolts.
  28. Assemble the transaxle assembly to the engine assembly. (Refer to )
  29. Install the engine and transaxle assembly to the vehicle. (Refer to ENGINE AND TRANSAXLE ASSEMBLY in this group)
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