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HOMESERVICE MANUALSHYUNDAI2009SONATA SE, 3.3 FREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALMECHANICALCYLINDER BLOCK - 3.3LREASSEMBLY
2009 Hyundai Sonata SE, 3.3 F

Cylinder Block - 3.3L: Reassembly

2009 Hyundai Sonata SE, 3.3 FSECTION Reassembly
NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  • Replace all gaskets, O-rings and oil seals with new parts.
  1. Assemble piston and connecting rod.
    1. Use a hydraulic press for installation.
    2. The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
    Fig 1: Identifying Piston Front Mark And Connecting Rod Front Mark
    G06107373Courtesy of HYUNDAI MOTOR CO.
  2. Install piston rings.
    1. Install the oil ring spacer and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
    3. Position the piston rings so that the ring ends are as shown.
    Fig 2: Identifying Compression Rings Code Mark
    G04879604Courtesy of HYUNDAI MOTOR CO.
  3. Install connecting rod bearings.
    1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
    2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
    Fig 3: Identifying Connecting Rod And Connecting Rod Cap
    G04879605Courtesy of HYUNDAI MOTOR CO.
  4. Install main bearings.
    NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
    1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A).
      Fig 4: Identifying Upper Bearings
      G04879606Courtesy of HYUNDAI MOTOR CO.
    2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
  5. Install thrust bearings.

    Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

    Fig 5: Identifying Thrust Bearings
    G04879607Courtesy of HYUNDAI MOTOR CO.
  6. Place crankshaft on the cylinder block.
    Fig 6: Identifying Crankshaft On Cylinder Block
    G04879583Courtesy of HYUNDAI MOTOR CO.
  7. Place main bearing caps on cylinder block.
  8. Install main bearing cap bolts.
    1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.

      Tightening torque 

      Main bearing cap bolt

      49.00 N.m (5.0 kgf.m, 36.16lb-ft) + 90° (1 ~ 8)

      19.60 N.m (2.0 kgf.m, 14.46lb-ft)+ 120° (9 ~ 16)

      29.40 ~ 31.36N.m (3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14 lb-ft) (17 ~ 22)

      NOTE:
      • Always use new main bearing cap bolt.
      • If any of the bearing cap bolts in broken or deformed, replace it.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.