Complete replacement of main bearings requires engine removal, disassembly to crankshaft level, installation of new bearings with plastigauge verification, and reassembly with critical torque specifications.

Warnings

Tools required

Parts

• Main bearing set (standard or oversized) × 1 — Use OEM specification - measure journals first
• Thrust bearing set × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pump gasket/O-rings × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Coolant × 1 — Hyundai/Kia Long Life Coolant (Green)
• Engine oil × 1 — Hyundai Genuine 0W-20
• RTV silicone sealant (OEM specified) × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks
2. Disconnect negative battery cable, then positive cable
3. Remove engine cover and drain coolant into appropriate container
4. Drain engine oil and remove oil filter
5. Remove front bumper cover for radiator and accessory access
6. Remove hood after marking hinge positions for reinstallation alignment
7. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
8. Disconnect all engine harness connectors, label for reassembly
9. Remove air intake system completely
10. Disconnect fuel lines using proper disconnect tools
11. Raise and secure vehicle on lift or jack stands rated for vehicle weight
12. Remove front wheels and front subframe skid plate if equipped
13. Drain transmission fluid and transfer case fluid
14. Document all vacuum lines, coolant hoses, and electrical connections with photos

Procedure

1. 1

   Remove exhaust system and front driveshaft
   Disconnect exhaust system at manifold flanges. Remove front propeller shaft from transfer case and front differential (AWD). Support exhaust with jack and remove hangers, then lower assembly. Remove heat shields as needed for access.
2. 2

   Disconnect transmission and support powertrain
   Support transmission with transmission jack. Remove starter motor and mark flexplate/flywheel position relative to torque converter or pressure plate. Remove all transmission-to-engine mounting bolts. Disconnect shift cables, cooler lines, and electrical connectors from transmission. Support engine from above using engine hoist with load leveler attached to factory lifting points.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
3. 3

   Remove engine mounts and accessories
   Remove engine mount bolts from frame rails and crossmember. Disconnect power steering pressure sensor (electric system, no lines). Remove alternator, A/C compressor (leaving lines attached and securing aside), and all accessory drive components. Remove upper and lower radiator hoses, heater hoses, and all remaining coolant connections.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Extract engine from vehicle
   With all connections verified disconnected and transmission separated, carefully raise engine using hoist while guiding it forward and up. Have assistant monitor for any remaining connections. Tilt engine as needed using load leveler to clear chassis and fenders. Once clear, lower engine onto engine stand and secure using engine stand mounting bolts.
   ⚠️Ensure hoist is rated for engine weight (approximately 400 lbs) and chains/straps are properly secured before lifting.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove timing chain cover and accessories
   With engine on stand, remove valve cover. Remove crankshaft pulley and harmonic balancer using proper puller (do not hammer). Remove timing chain cover bolts in reverse of tightening sequence. Remove timing chain tensioner, guides, and timing chain after marking timing alignment. Remove oil pump drive chain if equipped.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
6. 6

   Remove cylinder head and oil pan
   Remove cylinder head bolts in proper sequence (reverse of tightening pattern in service manual). Lift cylinder head off block and place on clean surface with combustion chambers facing up. Remove oil pan bolts in reverse sequence and carefully separate oil pan from block. Remove oil pump pickup tube and oil pump assembly.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
7. 7

   Remove pistons and connecting rods
   Mark each connecting rod and cap with cylinder number using metal stamps (if not already marked). Remove connecting rod cap bolts and caps, keeping each cap with its rod. Push pistons up and out of cylinders from below. Store each piston/rod assembly in numbered bags or labeled containers to ensure correct reinstallation location.
8. 8

   Remove flywheel and rear main seal
   Mark flywheel position relative to crankshaft flange. Remove flywheel bolts in star pattern sequence. Remove flywheel and set aside. Carefully pry out rear main seal using seal removal tool or careful prying. Clean rear seal bore thoroughly.
   ⚠Flywheel bolts are torque-to-yield and must be replaced during reassembly.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
9. 9

   Remove main bearing caps and crankshaft
   Verify main bearing caps are marked with cylinder number and directional arrow (should point toward front of engine). Remove main bearing cap bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift main bearing caps off, keeping them in order. With all caps removed, carefully lift crankshaft straight up out of block. Place on clean padded surface.
   ⚠Main bearing caps must be reinstalled in exact same position and orientation. Mark if not already clearly marked.
   Torque spec

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

    Inspect and measure crankshaft journals
    Thoroughly clean all crankshaft main journals with solvent and lint-free cloth. Inspect for scoring, heat discoloration, or damage. Using micrometer, measure each main journal diameter in multiple locations (top, bottom, front, rear) to check for taper and out-of-round condition. Record all measurements. Main journals must be within 0.0004 inch tolerance for roundness. If journals are worn beyond standard specification, crankshaft must be reground and undersized bearings used.
    ⚠If any journal is out of specification, crankshaft must be professionally reground or replaced. Do not attempt to reuse out-of-spec crankshaft.
11. 11

    Inspect block and measure bearing bores
    Clean engine block main bearing bores thoroughly with solvent and compressed air. Inspect for cracks, scoring, or damage. Using dial bore gauge, measure each main bearing bore for roundness and taper. All bores must be within specification. Check block deck surface for warpage using precision straightedge and feeler gauges. Verify oil passages are clean and clear using compressed air and small brushes.
12. 12

    Install new main bearings and verify clearance
    Install new upper main bearing shells into block saddles, ensuring bearing tabs engage notches properly. Do NOT use any oil or lubricant for plastigauge measurement. Cut strips of plastigauge to journal width and place across each crankshaft journal. Carefully lower crankshaft into block. Install lower bearing shells into main caps (dry, no oil). Install main caps in correct position and orientation with arrows facing front. Install NEW main bearing cap bolts and torque in proper sequence to 55 lb-ft, then apply angle torque per service manual specification (typically 90 degrees additional). Do NOT rotate crankshaft.
    ⚠Absolutely no oil or lubricant on bearings during plastigauge measurement or readings will be inaccurate.
    ⚠Do not rotate crankshaft with plastigauge installed or measurement will be compromised.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Check bearing clearances with plastigauge
    Remove main bearing cap bolts and carefully lift each main cap. Remove plastigauge from journals and measure width using plastigauge envelope scale. Typical clearance specification is 0.0008-0.0018 inches. Record all measurements. If clearances are too tight, verify correct bearing size and journal measurements. If clearances are too loose, undersized bearings may be required. All clearances must be within specification before proceeding.
    ⚠Out-of-specification bearing clearances will result in immediate engine failure. Do not proceed if clearances are incorrect.
14. 14

    Final main bearing installation
    Once clearances are verified, remove crankshaft and wipe all plastigauge residue from journals and bearings with clean lint-free cloth. Apply clean engine assembly lubricant (not standard motor oil) to all bearing surfaces generously. Install upper bearings in block, ensuring thrust bearing is in correct position (typically center main). Lower crankshaft into block. Apply assembly lubricant to lower bearing shells and install in main caps. Verify thrust bearing alignment. Install main caps with arrows facing front in correct numerical order.
15. 15

    Torque main bearing caps and verify crankshaft endplay
    Install NEW main bearing cap bolts. Following service manual torque sequence (typically center out pattern), torque all main cap bolts to 55 lb-ft, then apply angle torque specification (typically 90 degrees additional) in same sequence. Using dial indicator on crankshaft snout, pry crankshaft fully forward and zero indicator, then pry fully rearward and measure endplay. Specification is typically 0.002-0.010 inches. Verify crankshaft rotates smoothly by hand with no binding or rough spots.
    ⚠Excessive endplay indicates incorrect thrust bearing installation. Insufficient endplay indicates thrust bearing is damaged or incorrect.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
16. 16

    Reassemble lower engine components
    Install new rear main seal using seal driver, ensuring even installation depth. Install pistons and connecting rods in correct cylinder numbers with proper orientation (usually mark faces front). Install oil pump with new gasket, then oil pump pickup tube with new O-ring. Clean all oil pan mating surfaces thoroughly and install new oil pan gasket with light application of RTV at corners per service manual. Install oil pan bolts in proper sequence.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
17. 17

    Install flywheel and timing components
    Install flywheel aligned with marks made during disassembly, using NEW flywheel bolts. Torque in star pattern sequence. Install timing chain, guides, and tensioner per service manual timing marks. Install timing chain cover with new gasket, applying RTV sealant at block-to-head mating areas as specified. Install crankshaft harmonic balancer and pulley. Install valve cover with new gasket.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Cover Bolts16 Nm (12 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)
18. 18

    Reinstall engine and reconnect systems
    Reverse engine removal procedure to reinstall engine into vehicle. Align engine with transmission and install transmission-to-engine bolts in proper sequence. Install all engine mounts and torque to specification. Reconnect all accessories, drive belts, exhaust system, driveshafts, coolant hoses, fuel lines, vacuum lines, and electrical connections. Install air intake system and engine cover.
    Torque spec

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

    Mounting Bolts27 Nm (20 lb-ft)
19. 19

    Fill fluids and perform initial startup
    Fill engine with 5 quarts Hyundai Genuine 0W-20 oil and install new oil filter. Fill cooling system with 10 quarts Hyundai/Kia Long Life Coolant. Refill transmission and transfer case with proper fluids. Install oil drain plug with new crush washer. Double-check all connections and torque specifications. Reconnect battery. Prime oil system by cranking engine with fuel pump fuse removed and spark plugs out until oil pressure gauge shows pressure. Reinstall spark plugs and fuel pump fuse. Start engine and verify oil pressure immediately.
    ⚠️Monitor oil pressure gauge immediately upon startup. If no pressure within 10 seconds, shut down engine immediately to prevent damage.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Torque all fasteners to specification in proper sequence - main bearing cap torque sequence is critical
2. Use all new torque-to-yield bolts for main caps and flywheel - never reuse TTY fasteners
3. Apply proper assembly lubricant to bearings, not standard motor oil during assembly
4. Verify crankshaft rotates freely by hand after main cap installation before proceeding
5. All gaskets and seals must be replaced - do not reuse old gaskets
6. Follow service manual timing chain installation marks exactly
7. Bleed cooling system completely to remove air pockets after filling

Verification

• Start engine and verify immediate oil pressure indication (should reach 10+ psi within seconds)
• Listen for any unusual noises such as knocking, ticking, or grinding that would indicate bearing problems
• Allow engine to reach operating temperature while monitoring for leaks at oil pan, timing cover, and rear main seal
• Check for coolant leaks at all hose connections and gasket surfaces
• Verify proper operation of all engine accessories and systems
• Road test vehicle under light load initially, then progressively increase load while monitoring for unusual noises or vibrations
• After 500 miles, change engine oil and filter, then recheck for any leaks or unusual operation
• Monitor oil pressure at idle and under load to ensure readings are within normal specification

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