Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE:

Thoroughly clean all parts to 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.

Install the piston cooling jet (A).
Tightening torque:

7.8 ~ 12.7 N.m (0.8 ~ 1.3kgf.m, 5.8 ~ 9.4 lb-ft)

Fig 1: Piston Cooling Jet
Courtesy of HYUNDAI MOTOR AMERICA
Assemble the piston and connecting rod.
1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (A) must face the timing chain side of the engine.
  
  Fig 2: Piston Front Mark
  Courtesy of HYUNDAI MOTOR AMERICA
Install the piston rings.
1. Install the oil ring coil spring 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 the illustration.
  
  Fig 3: Piston Rings
  Courtesy of HYUNDAI MOTOR AMERICA
Install the connecting rod bearings.
1. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B).
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
  
  Fig 4: Connecting Rod Cap And Bearing
  Courtesy of HYUNDAI MOTOR AMERICA
Install the crankshaft main bearings.
1. Align the bearing claw with the claw groove of the cylinder block, push in the five upper bearings (A).
  NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
  
  Fig 5: Crankshaft Upper Bearings
  Courtesy of HYUNDAI MOTOR AMERICA
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
Install the thrust bearing.
Install the thrust bearing (A) on the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 6: Thrust Bearings
Courtesy of HYUNDAI MOTOR AMERICA
Place the crankshaft on the cylinder block.
Place the main bearing caps on the cylinder block.
Install the main bearing cap bolts.
NOTE: The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts in broken or deformed, replace it.
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, in several passes, in the sequence shown in the illustration.
  Tightening torque:
  
  17.7~21.6 Nm (1.8~2.2kgf.m, 13.0~15.9 lb-ft) + 88~92°
  
  Fig 7: Main Bearing Cap Mounting Bolts Tightening Sequence
  Courtesy of HYUNDAI MOTOR AMERICA
  
  CAUTION: Do not reuse the main bearing cap bolts.
3. Check that the crankshaft turns smoothly.
Check the crankshaft end play.
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.
1. Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
2. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
  Tightening torque:
  
  17.7~21.8 Nm (1.8~2.2kgf.m, 13.0~15.9 lb-ft) + 88~92°
  
  CAUTION: Do not reuse the connecting rod cap bolts.
Apply the sealant on the ladder frame.

Fig 8: Ladder Frame Sealant Applying Area
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
- Apply the sealant, THREE-BOND 1217H or LOCTITE 5900H on the ladder frame rail portion and install it with in five minutes.
- If when sealant is applied to cylinder block bottom position, sealant position to be same with position that is applied to ladder frame rail position.
- Apply sealant along the inner line of the bolt holes.
Install the ladder frame (A).
Tightening torque:

18.6 ~ 24.2 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft)

Fig 9: Ladder Frame
Courtesy of HYUNDAI MOTOR AMERICA
Install the rear oil seal.
(Refer to "REAR OIL SEAL ")
Install the oil screen (A).
Install a new gasket and oil screen with 2 bolts.

Tightening torque:

19.6 ~ 26.5 N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5 lb-ft)

Fig 10: Oil Screen
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil pan.
(Refer to "OIL PAN ")
Install the oil pressure switch.
(Refer to OIL PRESSURE SWITCH ) .
Install the knock sensor and the oil filter.

Fig 11: Knock Sensor And Oil Filter
Courtesy of HYUNDAI MOTOR AMERICA
Install the oil level gauge tube.
Install the water jacket.
(Refer to "WATER JACKET SEPARATOR ")
Install the timing chain.
(Refer to TIMING CHAIN ) .
Install the cylinder head.
(Refer to CYLINDER HEAD ) .
Disconnect the engine stand.
AT: Install the drive plate.
(Refer to "DRIVE PLATE ")
MT: Install the flywheel.
(Refer to "FLYWHEEL ")
Install the engine.
(Refer to ENGINE AND TRANSMISSION ASSEMBLY )