Complete removal and reinstallation of the crankshaft from a 2016-2024 Hyundai Tucson with 2.5L I4 AWD engine, requiring engine removal, complete disassembly of rotating assembly, and precision reassembly.

Warnings

Tools required

Parts

• Crankshaft (if replacing) × 1 — Use OEM specification
• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Oil pump O-ring and gasket kit × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Valve cover gasket set with spark plug tube seals × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Engine oil × 2 — 0W-20 Hyundai Genuine
• Engine coolant × 2 — Hyundai/Kia Long Life Green
• RTV silicone sealant (Hyundai specified) × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai SP-IV-M ATF — 10 qt
• 75W-90 GL-5 Gear Oil (Front Diff) — 1.5 qt
• 75W-90 GL-5 Gear Oil (Rear Diff) — 2 qt
• Transfer Case Fluid — 2.5 qt

Preparation

1. Position vehicle on level ground with parking brake applied and front wheels chocked
2. Disconnect negative battery cable and isolate terminal
3. Drain engine oil completely and remove oil filter
4. Drain engine coolant from radiator and block drain plugs into appropriate containers
5. Remove engine cover and disconnect all electrical connectors, labeling for reinstallation
6. Remove air intake system, throttle body, and intake manifold
7. Disconnect fuel lines after relieving fuel system pressure (fuel rail Schrader valve)
8. Remove exhaust manifold and downpipe assembly
9. Drain automatic transmission fluid and disconnect transmission cooler lines
10. Remove front driveshaft from transfer case and mark position for reinstallation
11. Support transmission with transmission jack
12. Remove engine mounts and transmission-to-engine mounting bolts
13. Attach engine hoist with load leveler to engine lifting points
14. Carefully lift engine and transmission assembly from vehicle, separating transmission once clear
15. Mount engine securely on engine stand using appropriate adapter plate
16. Position engine stand for comfortable working access to all sides

Procedure

1. 1

   Remove timing components and front accessories
   Remove accessory drive belts, crankshaft pulley, and timing cover. Use crankshaft holding tool or impact wrench to remove harmonic balancer bolt (left-hand threads). Remove timing chain tensioner, guides, and timing chain after locking camshafts in TDC position with appropriate timing tools. Remove timing cover bolts in reverse sequence, noting different bolt lengths and locations.
2. 2

   Remove cylinder head assembly
   Remove valve cover and all related components. Loosen cylinder head bolts in reverse of tightening sequence (consult service manual for specific pattern). Remove cylinder head assembly with intake and exhaust camshafts. Place on clean surface with gasket surface protected. Inspect head gasket for failure patterns that may indicate crankshaft or bearing issues.
3. 3

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse sequence and carefully separate pan from block using plastic scraper to avoid damaging sealing surfaces. Remove oil pump pickup tube, then remove oil pump mounting bolts. Remove oil pump assembly and inspect drive mechanism. Remove front main seal housing from engine block.
4. 4

   Remove pistons and connecting rod assemblies
   Rotate crankshaft to position each piston at bottom dead center individually. Mark each connecting rod cap and rod with cylinder number and orientation (mark faces that mate together). Remove connecting rod bolts and caps, keeping each set with its respective rod. Push piston and rod assembly out through top of cylinder bore. Store each assembly in order with bearings kept with original rod and cap. Inspect rod bearings for wear patterns.
5. 5

   Remove rear main seal housing and flexplate
   Remove rear main seal housing bolts and carefully remove housing. Use flywheel holding tool or wedge to prevent rotation. Remove flexplate bolts in star pattern (automatic transmission). Remove flexplate and inspect for cracks or damaged teeth. Mark flexplate orientation to crankshaft for reinstallation.
6. 6

   Remove main bearing caps and crankshaft
   Carefully mark each main bearing cap with cylinder number and directional arrow pointing toward front of engine. Main caps MUST be reinstalled in exact original positions and orientations. Loosen main bearing cap bolts evenly in multiple passes from outer caps working toward center. Remove main bearing caps and set aside with bearings in place for inspection. Carefully lift crankshaft straight up and out of engine block. Place on clean, protected surface for inspection.
7. 7

   Inspect and measure crankshaft and block
   Thoroughly clean crankshaft journals with brake cleaner and lint-free cloths. Inspect all journal surfaces for scoring, discoloration, or wear. Use micrometer to measure all main and rod journals at multiple points to check for out-of-round (maximum 0.001 inch) and taper. Measure crankshaft end play specification (typical 0.002-0.009 inch). Use dial bore gauge to measure main bearing bores in block for out-of-round or distortion. If measurements are out of specification, crankshaft requires machine shop services for grinding and block may require line boring. Clean engine block thoroughly, removing all bearing material and debris from bearing saddles and oil passages.
8. 8

   Inspect bearings and select proper clearances
   Examine all removed bearings for wear patterns, scoring, or embedded material. Wear patterns indicate alignment or lubrication issues that must be corrected. Select appropriate bearing size based on crankshaft journal measurements (standard, 0.25mm undersize, or 0.50mm undersize). Install main bearing inserts DRY into block saddles and caps, ensuring bearing tabs engage notches properly. Install upper thrust bearing halves in center main position. Do not apply oil yet for clearance checking.
9. 9

   Check main bearing clearances with Plastigauge
   Place strips of Plastigauge across each main journal parallel to crankshaft axis. Carefully lower crankshaft into position in block. Install main bearing caps in correct positions with directional marks aligned. Install NEW main bearing cap bolts finger tight, then torque to 75 Nm in sequence from center cap outward. Do NOT rotate crankshaft. Carefully remove caps and measure crushed Plastigauge width against package scale. Acceptable clearance is 0.001-0.003 inches (0.025-0.075mm). If clearance is too tight or too loose, select different bearing size and retest. Remove all Plastigauge material completely before final assembly.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Install crankshaft with final torque sequence
    Clean all bearing surfaces and crankshaft journals with brake cleaner and lint-free cloths. Apply clean engine assembly lube or fresh 0W-20 oil to all main bearing surfaces (upper and lower). Verify thrust bearing halves are properly positioned in center main location. Carefully lower crankshaft into block, ensuring journals seat properly in bearings. Install main bearing caps in correct positions with alignment marks oriented properly. Install NEW TTY main bearing cap bolts and hand-tighten all bolts first. Torque main cap bolts to 75 Nm in proper sequence (center cap first, then alternating outward). Using torque angle gauge, rotate each bolt an additional 90 degrees in same sequence. Verify crankshaft rotates freely by hand with smooth resistance. Check crankshaft end play with dial indicator (specification 0.05-0.23mm).
    ⚠️Main bearing cap bolts are torque-to-yield (TTY) and MUST be replaced with new bolts. Reusing old bolts will result in engine failure.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
11. 11

    Install connecting rod and piston assemblies
    Clean all connecting rod bearing surfaces thoroughly. Install NEW connecting rod bearings into rods and caps, ensuring tabs engage properly. Apply engine assembly lube to bearings and crankshaft rod journals. For each piston assembly, compress piston rings with ring compressor and carefully insert piston into its original cylinder bore with directional mark toward front of engine. Guide connecting rod onto crankshaft journal, ensuring rod and cap match marks align. Install NEW TTY connecting rod bolts. Torque to 45 Nm, then rotate an additional 90 degrees with torque angle gauge. Verify each rod has proper side clearance on crankshaft (0.10-0.25mm). Confirm crankshaft still rotates freely after installing all rod assemblies.
    ⚠️Connecting rod bolts are torque-to-yield (TTY) and MUST be replaced with new bolts.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install rear main seal housing and flexplate
    Install new rear main seal into seal housing using seal installation tool to ensure even seating without damage. Apply thin bead of RTV sealant to seal housing mating surface per Hyundai specification. Install seal housing and torque bolts to 12 Nm in cross pattern. Allow RTV to cure for specified time. Install flexplate to crankshaft in original orientation using alignment marks. Install flexplate bolts and torque to 85 Nm in star pattern to ensure even clamping. Use holding tool to prevent crankshaft rotation during tightening.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
13. 13

    Install oil pump and front seal housing
    Install new O-rings and gaskets on oil pump assembly. Prime oil pump by filling with clean engine oil and rotating by hand. Install oil pump to block and torque mounting bolts to 12 Nm. Install oil pump pickup tube with new O-ring and torque to 12 Nm. Install new front crankshaft seal into front seal housing using installation tool. Apply thin bead of RTV to housing mating surface and install housing, torquing bolts to 12 Nm in cross pattern.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)
14. 14

    Install oil pan
    Thoroughly clean oil pan and block mating surfaces, removing all old gasket material. Install new oil pan gasket, ensuring proper alignment with bolt holes. Apply small dabs of RTV at corners where front seal housing and rear seal housing meet block. Position oil pan and install bolts hand-tight. Torque oil pan bolts to 12 Nm in proper sequence (spiral pattern from center outward). Install oil drain plug with new crush washer and torque to 35 Nm.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
15. 15

    Install timing components
    Install timing chain guides and torque bolts to 12 Nm. Ensure timing chain tensioner is compressed and locked with pin or clip. Install timing chain onto crankshaft sprocket and route around guides. Clean timing cover mating surface thoroughly and install new gasket. Apply RTV sealant at specific locations per service manual. Install timing cover and torque 8mm bolts to 25 Nm and 10mm bolts to 45 Nm in proper sequence. Install new crankshaft seal if not already in timing cover. Install harmonic balancer onto crankshaft, ensuring keyway aligns. Install NEW harmonic balancer bolt and torque to 180 Nm using holding tool or impact wrench. Release timing chain tensioner pin to apply tension.
    ⚠Verify timing marks are properly aligned before releasing chain tensioner to prevent valve-to-piston contact.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
16. 16

    Install cylinder head and valve train
    Clean cylinder head and block mating surfaces thoroughly. Install new cylinder head gasket with proper orientation (TOP marking facing up). Carefully position cylinder head onto block, aligning dowel pins. Install NEW TTY cylinder head bolts and hand-tighten in sequence. Torque to 65 Nm in three progressive passes following proper sequence (center outward), then rotate each bolt an additional 90 degrees plus 45 degrees using angle gauge in same sequence. Install valve cover with new gasket and torque bolts to specification. Reinstall all cylinder head components including sensors.
    ⚠️Cylinder head bolts are torque-to-yield (TTY) and MUST be replaced with new bolts.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
17. 17

    Complete engine assembly and reinstallation
    Install all remaining engine components including intake manifold, exhaust manifold, accessories, and sensors. Fill engine with 5 quarts of Hyundai Genuine 0W-20 oil and new oil filter. Mate transmission to engine using new transmission-to-engine bolts torqued to 55 Nm. Using engine hoist, carefully lower engine and transmission assembly into vehicle. Install engine mounts and torque mounting bolts to 47 Nm for critical mounts and 27 Nm for secondary mounts. Reconnect all driveshafts, electrical connectors, fuel lines, coolant hoses, and exhaust components. Refill cooling system with 10 quarts of Hyundai/Kia Long Life Green coolant. Refill transmission with 10 quarts of Hyundai SP-IV-M ATF. Refill front differential with 1.5 quarts 75W-90 GL-5, rear differential with 2.0 quarts 75W-90 GL-5, and transfer case with 2.5 quarts of transfer case fluid.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)

Reassembly

1. Ensure all torque-to-yield (TTY) fasteners have been replaced with new components including main bearing cap bolts, connecting rod bolts, cylinder head bolts, and crankshaft pulley bolt
2. Verify all bearing clearances were checked and documented within specification before final assembly
3. Confirm crankshaft rotates freely by hand through complete revolution with all components installed
4. Double-check timing chain alignment and verify tensioner is properly engaged
5. Verify all electrical connectors are properly seated and locked
6. Confirm all fluid levels are correct: engine oil, coolant, transmission fluid, differentials, and transfer case
7. Check that all hose clamps, fuel line connections, and exhaust connections are properly tightened

Verification

• Before starting engine, remove spark plugs and crank engine with starter motor for 10 seconds to prime oil system. Verify oil pressure light extinguishes
• Reinstall spark plugs and start engine. Monitor for immediate oil pressure indication (should be present within 2-3 seconds)
• Allow engine to idle and inspect for any oil, coolant, or fuel leaks around all reassembled components
• Monitor engine temperature and verify cooling system is functioning properly without air pockets
• Listen for any abnormal noises including knocking, ticking, or rattling that could indicate bearing or assembly issues
• After initial warm-up and cool-down, recheck all fluid levels and top off as necessary
• Perform test drive and monitor engine operation under various loads and RPM ranges
• After 500 miles, change engine oil and filter to remove any assembly residue or break-in contaminants
• Inspect for leaks after test drive and verify no oil consumption or coolant loss occurs

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