Front Case And Lubrication System: Reassembly

1. Apply engine oil to the gear and align the two timing marks.
   Fig 1: Identifying Timing Marks

   Courtesy of HYUNDAI MOTOR CO.
2. Using the special tool, the crankshaft front oil seal installer (09214-32000), install the crankshaft front oil seal into the front case.
   Fig 2: Installing Front Crankshaft Oil Seal

   Courtesy of HYUNDAI MOTOR CO.
3. Set the special tool (09214-32100) on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
   Fig 3: Identifying Special Tool

   Courtesy of HYUNDAI MOTOR CO.
4. Install a new front case gasket to the front case assembly and tighten the flange bolts temporarily.
   Fig 4: Installing Front Case

   Courtesy of HYUNDAI MOTOR CO.
5. Install the front case assembly with a new gasket. Tighten bolts to the specified torque.

   Front case assembly 

   Tightening torque :

   20 ~ 27 Nm (200 ~ 270 kg.cm, 14 ~ 20 lb.ft)

   Fig 5: Identifying Front Case Bolts

   Courtesy of HYUNDAI MOTOR CO.
6. Insert a screw driver into the plug hole in left side of cylinder block. After verifying that the shaft is in the proper position, replace the bolt and tighten it.
   Fig 6: Verifying Shaft Position

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7. Install a new O-ring to the groove of the front case.
8. Using a special tool, install the plug case and tighten it to the specified torque.
   Fig 7: Installing Plug Case

   Courtesy of HYUNDAI MOTOR CO.

   Plug cap 

   Tightening torque : 20 ~ 27 Nm (200 ~ 270 kg.cm, 14 ~ 20 lb.ft)

9. Apply sealant to the groove of the pan flange as shown.
   NOTE:

   1. Apply sealant approximately 4 mm (0.16 in.) in thickness.
   2. After the application of the sealant, install the oil pan within 15 minutes.
   Fig 8: Oil Pan Bolt Tightening Sequence

   Courtesy of HYUNDAI MOTOR CO.
10. Note the difference in bolt lengths at the locations shown.

    Install the upper and lower oil pans and tighten the bolts to the specified torque.

    Tightening torque 

    Oil pan bolt : 10 ~ 12 Nm (100 ~ 120 kg.cm, 7 ~ 9 lb.ft)

11. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.

Sealant : Threebond 1104 or equivalent

Tightening torque 

Oil pressure switch :

8 ~ 12 Nm (80 ~ 120 kg.cm, 6 ~ 9 lb.ft)

Fig 9: Installing Oil Pressure Switch

Courtesy of HYUNDAI MOTOR CO.