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Home >> Hyundai >> 2003 >> Accent Base >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 1.6L 4-Cylinder Engine >> Main Moving System >> Piston >> Reassembly
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Main Moving System: Piston: Reassembly

  1. Install the spacer.
    Fig 1: Installing Spacer (1 Of 2)
    G00965784Courtesy of HYUNDAI MOTOR CO.
    Fig 2: Installing Spacer (2 Of 2)
    G00965785Courtesy of HYUNDAI MOTOR CO.
  2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with a finger on the portion to be inserted into the groove (as illustrated).
    CAUTION: Do not use a piston ring expander when installing side rail.
  3. Install the lower side rail by the same procedure described in Step 2.
    Fig 3: Installing Side Rail
    G00965786Courtesy of HYUNDAI MOTOR CO.
  4. Apply engine oil around the piston and piston grooves.
  5. Using a piston ring expander, install the No. 2 piston ring.
  6. Install the No. 1 piston ring.
    Fig 4: Identifying Piston Rings
    G00965787Courtesy of HYUNDAI MOTOR CO.
  7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions.
  8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
    Fig 5: Identifying Piston Ring Gap Positioning
    G00965788Courtesy of HYUNDAI MOTOR CO.
  9. Install the upper main bearings in the cylinder block.
  10. Install the lower main bearings in the main bearing caps.
  11. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine.
  12. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
  13. When assembling, bolts should be fastened by the angle - torque controlled method as the following.
    1. Apply oil to the thread of nuts and spot areas.
    2. Tighten the connecting rod bolt.

    Tightening torque  Connecting rod cap nut: 32-35 N.m (320-350 kg.cm, 24-26 lb.ft)

    CAUTION: After removing the connecting rod bolt, do not use it again.
    When using a new bolt, do not tighten the bolt more than 3 times.
  14. Check the connecting rod side clearance.

    Connecting rod side clearance

    1. Standard: 0.10-0.25mm (0.0039-0.0098 in.)
    2. Limit: 0.4mm (0.0157 in.)
    Fig 6: Checking Connecting Rod Side Clearance
    G00965789Courtesy of HYUNDAI MOTOR CO.
  15. Install the oil screen.
  16. Install the oil pan.
  17. Install the cylinder head.
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