Complete replacement of all piston rings requires full engine disassembly, removing the cylinder head, oil pan, and extracting pistons from the block to install new rings with proper end gap specification.

Warnings

Tools required

Parts

• Piston ring set (all cylinders) × 1 — Use OEM specification for 2.5L Smartstream engine
• Cylinder head gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 1 — Use OEM specification - set of 8
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Spark plugs × 1 — Use OEM specification - set of 4
• RTV silicone sealant (Hyundai approved) × 1 — Use high-temp RTV for oil pan
• Coolant drain plug O-ring × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai SP-IV-M ATF — 2 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. Park vehicle on level surface and engage parking brake. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge.
2. Drain engine oil completely and remove oil filter. Drain coolant from radiator and engine block drain plugs.
3. Remove engine cover and air intake assembly including air filter box and intake ducting.
4. Remove front wheels and engine splash shields to access lower engine components.
5. Drain transmission fluid if necessary for torque converter access. Drain transfer case and both differentials on AWD models.
6. Label and disconnect all electrical connectors, vacuum lines, fuel lines, and coolant hoses connected to engine.
7. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls.
8. Remove exhaust system from manifold back to first connection point that allows engine removal clearance.
9. Support transmission with transmission jack or suitable stand before disconnecting from engine.
10. Attach engine hoist with appropriate lifting chains or brackets to factory engine lift points.
11. Remove engine mount bolts and carefully lift engine from vehicle, ensuring all connections are disconnected.

Procedure

1. 1

   Mount engine on stand and remove accessories
   Secure engine to engine stand using transmission bellhousing bolt holes. Remove alternator, A/C compressor (leave hoses attached and secure aside), power steering pump mounting bracket, starter motor, and all remaining accessory brackets. Remove ignition coils and spark plugs, labeling cylinder positions.
2. 2

   Remove valve cover and timing components
   Remove valve cover by loosening bolts in reverse of tightening sequence. Mark timing chain position relative to camshaft and crankshaft sprockets using paint pen or scribe marks. Remove timing chain tensioner, guides, and timing chain. Lock camshafts in position or remove if necessary per service manual. Remove timing chain cover.
   ⚠Take multiple photos of timing chain alignment before removal. Incorrect reassembly will destroy engine.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
3. 3

   Remove intake and exhaust manifolds
   Disconnect any remaining vacuum lines, breather hoses, and electrical connectors from intake manifold. Remove intake manifold bolts in sequence from outside to center and remove manifold with gaskets. Remove exhaust manifold heat shields and manifold bolts, then remove exhaust manifold and gaskets.
   Torque spec

   Gasket Bolts20 Nm (15 lb-ft)
4. 4

   Remove cylinder head
   Loosen cylinder head bolts in reverse of tightening sequence (from outside to center in three passes). Remove all cylinder head bolts - these are TTY and must be replaced. Carefully lift cylinder head from block, using plastic mallet to break gasket seal if needed. Place head on clean surface with combustion chambers facing up. Remove and discard head gasket.
   ⚠Do not pry between head and block surfaces. Damage to sealing surfaces will cause leaks.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Remove oil pan and oil pump
   With engine inverted or rotated on stand, remove oil pan bolts in reverse sequence. Break oil pan seal with plastic gasket scraper and remove pan. Remove oil pump pickup tube mounting bolt and remove tube. Remove oil pump mounting bolts and extract oil pump assembly. Inspect oil pump pickup screen for debris.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
6. 6

   Remove ridge and inspect cylinder bores
   Use cylinder ridge reamer to carefully remove ridge at top of each cylinder bore where piston rings have not traveled. Remove only enough material to eliminate ridge - do not cut into unworn cylinder wall. Clean cylinders thoroughly. Measure cylinder bore diameter at top, middle, and bottom in two perpendicular directions using dial bore gauge. Record measurements. Maximum taper specification is typically 0.002 inch; out-of-round maximum is 0.001 inch. If beyond specifications, cylinders require machining.
   ⚠Failure to remove cylinder ridge will damage rings during piston removal and installation.
7. 7

   Remove pistons and connecting rods
   Rotate crankshaft to position piston at bottom dead center. Mark connecting rod cap and rod with cylinder number using number stamps - markings must face same direction for reassembly. Remove connecting rod cap bolts (these are TTY and must be replaced). Remove rod cap and bearing. Push piston and rod assembly out through top of cylinder, guiding carefully to avoid scratching cylinder wall. Install rod cap back onto rod to maintain bearing clearance. Repeat for all four cylinders.
   ⚠Keep all connecting rods, caps, and bearings matched to their original cylinder. Mixing components will affect bearing clearances.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
8. 8

   Remove old piston rings
   Using piston ring expander pliers, carefully expand and remove top compression ring from first piston. Remove second compression ring, then oil control ring assembly (two rails and expander). Inspect ring grooves for carbon buildup, cracks, or wear. Use ring groove cleaner tool to remove all carbon deposits from grooves. Clean piston crown and skirt with solvent. Inspect piston for cracks, scuffing, or excessive wear. Repeat for all pistons.
   ⚠Piston rings are brittle. Avoid over-expanding rings during removal to prevent breakage and injury.
9. 9

   Measure and install new piston rings
   Insert top compression ring from new ring set into cylinder #1, pushing it square using inverted piston. Position ring approximately 0.5 inch below deck surface. Measure ring end gap using feeler gauge. Specification is typically 0.008-0.016 inch for compression rings. If gap is too tight, carefully file ring ends square. Repeat for second compression ring and oil control ring in each cylinder. Record all measurements. Once gaps are verified, install new rings on pistons using ring expander pliers. Install oil control ring expander first, then rails, then second compression ring, then top compression ring. Ensure ring gaps are staggered 120-180 degrees apart.
   ⚠Ring end gap too tight will cause ring breakage and engine damage. Too large will cause excessive blowby and oil consumption.
10. 10

    Install pistons into cylinders
    Lubricate cylinder walls, pistons, and rings with clean engine oil. Ensure connecting rod bearings are properly seated in rods. Install piston ring compressor over piston, compressing all rings into grooves. Position piston so directional marking (usually arrow or 'F') faces front of engine. Align connecting rod with crankshaft journal. Gently tap piston into cylinder using wooden dowel or plastic hammer handle while guiding connecting rod onto journal. Once piston enters cylinder, remove ring compressor. Guide connecting rod onto crankshaft journal. Install bearing into rod cap, install cap in correct orientation (match marks aligned), and install NEW connecting rod bolts finger tight. Repeat for all cylinders.
    ⚠Never force piston into cylinder. If resistance is felt, ring may not be fully compressed. Remove and retry to avoid ring breakage.
11. 11

    Torque connecting rod bolts
    Ensure crankshaft rotates freely with all pistons installed. Torque connecting rod cap bolts in two steps: First, torque all bolts to 45 Nm (33 lb-ft) in sequence from cylinder 1 to 4. Second, using angle gauge, rotate each bolt an additional 90 degrees in same sequence. Verify crankshaft still rotates freely after torquing. If binding occurs, disassemble and inspect for debris or misaligned bearings.
    ⚠️TTY bolts require torque-plus-angle tightening. Failure to follow sequence and angle specification can cause rod bolt failure and catastrophic engine damage.
    Torque spec

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

    Install oil pump and oil pan
    Clean all gasket surfaces on engine block and oil pan thoroughly. Install oil pump with new gasket or O-ring per design. Install oil pump pickup tube with new O-ring and torque pickup tube bolt. Apply thin bead of RTV silicone to oil pan gasket surfaces per service manual (typically corners where gasket meets). Install new oil pan gasket and position oil pan. Install oil pan bolts finger tight, then torque in sequence from center outward.
    ℹ️Allow RTV silicone to cure for time specified by manufacturer before adding oil, typically 1-2 hours.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
13. 13

    Install cylinder head
    Clean cylinder head and block mating surfaces completely - no oil or coolant residue. Verify block deck is flat and undamaged. Install new cylinder head gasket with alignment dowels. Carefully lower cylinder head onto block, aligning with dowels. Install NEW cylinder head bolts (TTY). Torque head bolts in three steps following service manual sequence (typically from center outward): Step 1 - torque all bolts to 65 Nm (48 lb-ft), Step 2 - rotate all bolts 90 degrees, Step 3 - rotate all bolts additional 45 degrees. Verify all bolts turned equally.
    ⚠️Cylinder head bolt sequence and torque-plus-angle procedure is critical. Improper torquing will cause head gasket failure and potential head warping.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
14. 14

    Install timing components and set timing
    Rotate crankshaft to TDC position for cylinder #1 (use service manual procedure). Install timing chain cover with new gasket. Align camshaft timing marks to specification. Route timing chain over crankshaft sprocket and both camshaft sprockets with slack on non-tensioner side. Verify all timing marks align precisely with marks made during disassembly or per service manual specifications. Install timing chain guides and tensioner. Remove tensioner locking pin or release mechanism. Rotate crankshaft two complete revolutions and verify all timing marks still align correctly.
    ⚠️Timing chain misalignment by even one tooth will cause valve-to-piston contact and severe engine damage. Triple-check alignment before proceeding.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)
15. 15

    Complete engine reassembly
    Install intake and exhaust manifolds with new gaskets. Install valve cover with new gasket. Install all accessory brackets, alternator, A/C compressor, power steering pump bracket, and starter motor. Install new spark plugs to specification (typically 25-30 Nm). Install ignition coils. Install all sensors removed during disassembly. Reinstall engine into vehicle using engine hoist, aligning with transmission. Install engine mount bolts and torque per specifications. Reconnect exhaust system, all electrical connectors, vacuum lines, fuel lines, and coolant hoses. Fill engine with 5 quarts Hyundai Genuine 0W-20 oil. Fill cooling system with 10 quarts Hyundai/Kia Long Life Coolant. Refill transmission, transfer case, and differentials to proper levels with specified fluids. Install new oil drain plug crush washer and torque drain plug. Reconnect battery.
    ℹ️Use only specified fluids. Incorrect oil viscosity or coolant type can cause engine damage or reduced performance.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

    Mounting Bolts27 Nm (20 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)

Reassembly

1. Torque all fasteners to specifications in proper sequence, replacing all TTY bolts with new OEM parts
2. Verify timing chain alignment multiple times during and after installation - rotate crankshaft two full revolutions and recheck
3. Allow RTV silicone sealant to cure fully before filling with fluids
4. Prime oil system by cranking engine with fuel pump fuse removed until oil pressure is indicated
5. Bleed cooling system completely using bleeder valves or procedure in service manual to prevent air pockets

Verification

• Start engine and verify oil pressure within 5 seconds - immediately shut down if no pressure indicated
• Allow engine to idle and listen for abnormal noises such as knocking, ticking, or rattling that could indicate incorrect assembly
• Monitor for coolant, oil, or fuel leaks around all gasket surfaces and connections
• Verify engine reaches normal operating temperature and thermostat opens properly
• Check for proper operation of all accessories including alternator charging and A/C compressor engagement
• Test drive vehicle and monitor for proper performance, no misfires, and no warning lights
• After 500 miles, re-check all fluid levels and inspect for any leaks or issues during break-in period
• Change engine oil and filter after 500-1000 miles to remove any break-in debris

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