Repair Procedures: Disassembly

CAUTION:

Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.
(Refer to General Information - "LIFT AND SUPPORT POINTS ")

NOTE:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Information

Mark all wiring and hoses to avoid misconnection.
Inspect the timing chain before removing the cylinder head.
Turn the crankshaft damper pulley so that the No. 1 piston is at top dead center (TDC).

Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")
Remove the transaxle assembly from the engine assembly.
(Refer to Automatic Transaxle System - "AUTOMATIC TRANSAXLE ")
Remove the drive plate and adapter plate.
(Refer to "DRIVE PLATE ")
Remove the rear oil seal case.
(Refer to "REAR OIL SEAL ")
Install the engine assembly to engine stand for disassembly.
Remove the surge tank.
(Refer to Intake and Exhaust System - "SURGE TANK ")
Remove the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")
Remove the timing chain.
(Refer to Timing System - "TIMING CHAIN ")
Remove the water temperature control assembly.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD ")
Remove the lower oil pan and upper oil pan.
(Refer to Lubrication System - "OIL PAN ")
Remove the oil pump.
(Refer to Lubrication System - "OIL PUMP ")
Remove the oil filter body.
(Refer to Lubrication System - "OIL FILTER BODY ")
Remove the baffle plate (A).

Courtesy of HYUNDAI MOTOR AMERICA
Check the connecting rod end play.
Check the connecting rod cap oil clearance.
Detach the piston and connecting rod assemblies from the cylinder block.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Remove the connecting rod bearing cap.
  Information
  - Mark the connecting rod, and caps to be able to reassemble in the original position and direction.
3. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
  Information
  - Keep the bearings, connecting rod and cap together.
  - Arrange the piston and connecting rod assemblies in the correct order.
  - Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
Disassemble the piston rings.
1. Using a piston ring expander, remove the 2 compression rings (A).
2. Remove the oil ring and coil spring (B) by hand.
  Information
  - Arrange the piston rings in the correct order only.

Disassemble the connecting rod from the piston.

Remove the snap ring (C) from the piston.
Using a press, remove the piston pin (D) from the piston.

Disassemble the piston (F) and connecting rod (E).

Courtesy of HYUNDAI MOTOR AMERICA