Repair procedures: Disassembly

Engine removal is required for this procedure.

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).

Remove the engine assembly from the vehicle. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Remove the transaxle assembly from the engine assembly.
(Refer to MT : REMOVAL - 2013 or REMOVAL - 2014 . AT : REMOVAL )
Manual transaxle: Remove the flywheel (A).

Fig 1: Flywheel (Manual Transaxle)
Courtesy of HYUNDAI MOTOR AMERICA

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

Fig 2: Flywheel (Automatic Transaxle)
Courtesy of HYUNDAI MOTOR AMERICA
Fix the engine to an engine stand for disassembly.
Remove the intake manifold and exhaust manifold.
(Refer to INTAKE & EXHAUST SYSTEM )
Remove the timing chain including the drive belt, the cylinder head cover, the alternator and the timing chain cover.
(Refer to REMOVAL )
Remove the cylinder head assembly.
(Refer to CYLINDER HEAD )
Remove the A/C compressor.
(Refer to REMOVAL )
Remove the water pump assembly.
(Refer to REMOVAL AND INSTALLATION )
Remove the water inlet fitting and the thermostat assembly.
(Refer to ENGINE COOLING SYSTEM )
Remove the knock sensor (A).
Remove the OPS (Oil pressure switch) (B).
Remove the CKPS (Crankshaft position sensor) (C).

Fig 3: Knock Sensor, Oil Pressure Switch And Crankshaft Position Sensor
Courtesy of HYUNDAI MOTOR AMERICA
Remove the oil filter.
(Refer to ENGINE LUBRICATION SYSTEM )
Remove the oil screen.
(Refer to ENGINE LUBRICATION SYSTEM )
Remove the rear oil seal (A).

Fig 4: Rear Oil Seal
Courtesy of HYUNDAI MOTOR AMERICA
Remove the lower crankcase.
1. Remove the lower crankcase mounting bolts.
  
  Fig 5: Lower Crankcase And Mounting Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
2. Remove the main bearing cap bolts.
  
  Fig 6: Main Bearing Cap Bolts
  Courtesy of HYUNDAI MOTOR AMERICA
Check the connecting rod side clearance.
Check the connecting rod bearing 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 and connecting rod assembly with 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.
Check the connecting rod bearing oil clearance.
Check the crankshaft end play.
Lift the crankshaft (A) out of the engine, being careful not to damage journals.

Fig 7: Crankshaft
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: Arrange the main bearings and thrust bearings in the correct order.
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 expander, remove the 2 compression rings.
2. Remove 2 side rails and the oil ring by hand.
  NOTE: Arrange the piston rings in the correct order.
Remove the snap rings and then disassemble the connecting rod from the piston.