Repair Procedures: Disassembly

M/T: remove flywheel.
A/T: remove drive plate.
Attach the engine to an engine stand for disassembly.
Remove timing chain. (Refer to TIMING SYSTEM .)
Remove cylinder head. (Refer to REMOVAL .)
Remove the oil dip stick (A).

Fig 1: Identifying Oil Dip Stick
Courtesy of HYUNDAI MOTOR CO.
Remove knock sensor (A).

Fig 2: Identifying Knock Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove oil pressure sensor (A).

Fig 3: Identifying Oil Pressure Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove the sensor cover and the CKP sensor (A).

Fig 4: Identifying CKP Sensor
Courtesy of HYUNDAI MOTOR CO.
Remove water pump.
Remove balance shaft module (oil pump).
Remove ladder frame (A).

Fig 5: Identifying Ladder Frame
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 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 thrust bearings in the correct order.

Fig 6: 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 2 side rails and the spacer by hand.
  NOTE: Arrange the piston rings in the correct order only.
Disconnect connecting rod from piston.