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Home >> Hyundai >> 2003 >> Tiburon Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 2.0L 4-Cylinder Engine >> Main Moving System >> Piston >> Reassembly
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Main Moving System: Piston: Reassembly

  1. Install the spacer.
    Fig 1: Identifying Side Rail & Spacer
    G00973371Courtesy of HYUNDAI MOTOR CO.
    Fig 2: Identifying Side Rail & Spacer Installation
    G00973372Courtesy 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).
    Fig 3: Installing Side Rail
    G00973373Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Do not use a piston ring expander when installing side rail.
  3. Install the lower side rail using the same procedure described in Step 2.
  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
    G00973374Courtesy 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 End Gap Positioning
    G00973375Courtesy 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

      1. Connecting rod cap nut: 50-53 N.m (37-39 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: 0.10-0.25 mm (0.0039-0.0098 in.)
    2. Limit: 0.4 mm (0.0157 in.)
  15. Install the oil screen.
  16. Install the oil pan.
  17. Install the cylinder head.
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