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Repair Procedures: Reassembly

NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  • Always use new gaskets, O-ring and oil seals.
  1. Assemble the piston and the connecting rod.
    1. Install the snap ring (A) in one side of the piston pin hole.
      G14076443Courtesy of HYUNDAI MOTOR AMERICA
    2. Align the piston front mark (A) and the connecting rod front mark (B).
      G14076444Courtesy of HYUNDAI MOTOR AMERICA
    3. Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod.
    4. Install the snap ring (B) in the other side after inserting the piston pin.
    G14076445Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Before inserting the piston pin, apply sufficient engine oil on the piston's outer surface, piston hole's inner surface and connecting rod's small-end bore.
    • When inserting, use caution not to damage or scratch the connecting rods' small-end hole, piston's pin hole and piston pin.
    • Install the snap ring surely so that the snap ring contacts the overall groove of the piston's pin hole.
    • Assemble so that the cut surface of the snap ring is located within the upper 45° range.
    G14076446Courtesy of HYUNDAI MOTOR AMERICA
  2. Install the piston rings.
    1. Install the oil ring expander and two 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.
    G14076447Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • The side rail is an asymmetric barrel type and install it so that DMC mark faces upward (Cylinder head side).

    At this time, paint identification mark should be positioned at the right side of ring cutting section.
  3. Install the connecting rod bearings.
    1. Align the bearing (B) claw with the groove of the connecting rod or bearing cap (A).
    2. Install the bearings (B) in the connecting rod and bearing cap (A).
    G14076448Courtesy of HYUNDAI MOTOR AMERICA
  4. Install the piston and connecting rod assembly.
    NOTE:
    • Before installing the piston, apply a coat of engine oil to the piston ring grooves and cylinder bores.
    • The piston front mark (A) and the connecting rod front mark (B) must face the timing chain side of the engine.
    G14076449Courtesy of HYUNDAI MOTOR AMERICA
    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.
      G14076450Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
    3. Install the connecting rod caps (A) with bearings, and tighten the bolts.

    Tightening torque: 

    17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft) + 68 - 72°

    G14076451Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Always use new connecting rod cap bolts.
  5. Assemble the other parts in the reverse order of disassembly.
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