Main Moving System: Piston: Reassembly

1. Install the spacer.
   Fig 1: Identifying Spacer Installation (1 Of 2)

   Courtesy of HYUNDAI MOTOR CO.
   Fig 2: Identifying Spacer Installation (2 Of 2)

   Courtesy 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, then press down with your finger the portion to be inserted into groove as illustrated.
   WARNING: Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure as described in Step No. 2.
   Fig 3: Installing Side Rail

   Courtesy of HYUNDAI MOTOR CO.
4. Apply engine oil around the piston and piston grooves.
5. Using piston ring expander, install the No. 2 piston ring.
6. Install the No. 1 piston ring.
   Fig 4: Identifying Piston Rings

   Courtesy of HYUNDAI MOTOR CO.
7. Place each piston ring end gap as far apart from its neighboring gaps as possible. Make sure that 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 Installation

   Courtesy of HYUNDAI MOTOR CO.
9. 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.
10. When the connecting rod cap is installed, make sure that the cylinder numbers put on the rod and cap at disassembly match.
11. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
12. Tighten the connecting rod cap nuts.

    Tightening torque 

    Connecting rod cap nuts :

    20 Nm (200 kg.cm, 15 lb.ft) + 90°

    Fig 6: Identifying Connecting Rod Bearing Notches

    Courtesy of HYUNDAI MOTOR CO.
13. Check the connecting rod side clearance.

Connecting rod side clearance 

Standard : 0.10 ~ 0.25 mm (0.004 ~ 0.0098 in.)

Limit : 0.4 mm (0.0157 in.)