This procedure covers the replacement of connecting rod bearings on the 2.5L I4 engine, requiring complete engine removal from the vehicle and partial disassembly to access the crankshaft and connecting rods.

Warnings

Tools required

Parts

• Connecting rod bearing set (standard or oversized as measured) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Complete engine gasket set recommended × 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 ground and apply parking brake
2. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
3. Remove engine cover and drain engine oil completely
4. Drain coolant from radiator and engine block drain plugs
5. Remove front bumper cover for access to radiator and AC condenser
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
7. Raise vehicle securely on jack stands at all four corners
8. Remove front wheels and engine undercovers
9. Document all electrical connector positions with photos before disconnection

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all engine wiring harnesses, vacuum lines, fuel lines, coolant hoses, and exhaust connections. Remove radiator, AC condenser (do not discharge AC system - unbolt condenser and support it aside), and power steering pump if equipped (this model uses electric steering). Disconnect transmission from engine. Remove engine mounting bolts and carefully lift engine using hoist with load leveler. Separate transmission if not already done.
2. 2

   Mount engine on stand and perform initial disassembly
   Secure engine to engine stand using transmission bellhousing bolt holes. Remove intake manifold, exhaust manifold, fuel rail, ignition coils, spark plugs, valve cover, timing chain cover, timing chain, and oil pump. Remove cylinder head completely to access cylinder bores and connecting rods from above. Mark all components for correct reassembly position.
3. 3

   Remove oil pan and windage tray
   Remove all oil pan bolts in reverse of tightening sequence. Carefully separate oil pan using plastic scrapers to avoid damaging sealing surfaces. Remove windage tray if equipped. Clean all gasket surfaces thoroughly with gasket scraper and brake cleaner.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
4. 4

   Inspect and measure crankshaft
   Rotate crankshaft to access each journal. Use micrometer to measure all four connecting rod journals in multiple positions to check for taper, out-of-round, and wear. Record all measurements. Journals must be within 0.001 inch of specification and free from scoring. If journals are damaged or out of specification, crankshaft must be removed and professionally machined.
   ⚠Do not proceed if crankshaft journals are scored, tapered beyond specification, or out-of-round. Professional machining is required.
5. 5

   Mark and remove connecting rod caps
   Verify that connecting rods and caps are numbered 1-4 from front to back, and that numbers face the same direction. If not marked, use permanent marker to clearly number them. Note the orientation of rod cap alignment - they only fit one way. Remove connecting rod bolts from cylinder 1 and carefully remove cap, keeping bearing insert with cap. Repeat for remaining cylinders, organizing parts in order.
   ⚠️Connecting rod caps are not interchangeable between cylinders or reversible. Incorrect installation will destroy the engine immediately upon startup.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
6. 6

   Remove pistons and inspect cylinders
   Check cylinder bores for ridge at top of ring travel. If significant ridge exists, use ridge reamer to remove it before pushing pistons out. Push each piston/rod assembly up and out through top of block. Keep pistons organized by cylinder number. Inspect cylinder bores for scoring or excessive wear. Measure bore diameter if excessive wear is suspected.
7. 7

   Inspect old bearings and clean components
   Carefully examine old bearing inserts for wear pattern, scoring, or metal flaking. Abnormal wear indicates other issues that must be addressed. Clean all connecting rod and cap bearing surfaces with brake cleaner and lint-free cloth. Clean crankshaft journals with brake cleaner ensuring all oil passages are clear. Blow out oil passages with compressed air.
8. 8

   Measure bearing clearance with Plastigage
   Install new bearing inserts into connecting rod and cap for cylinder 1 without lubrication. Place strip of Plastigage on crankshaft journal parallel to crankshaft centerline. Install rod cap in correct orientation with NEW connecting rod bolts. Torque bolts to 45 Nm (33 lb-ft) specification only - do not perform angle tightening for this measurement. Remove cap and compare Plastigage width to scale on package. Clearance should be 0.0008-0.0020 inches. If not within specification, bearing size must be changed.
   ⚠Do not rotate crankshaft with Plastigage installed. This will give false readings.
   ℹ️Use new bolts for Plastigage measurement since TTY bolts will be torqued twice (once for measurement, once for final assembly).
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Install connecting rod bearings
   Remove Plastigage completely from journal and bearing. Wipe bearings and journal clean with lint-free cloth. Install correct size bearing inserts into connecting rod and cap, ensuring bearing tabs engage slots properly. Lubricate bearings and crankshaft journal generously with clean engine oil. Install piston/rod assembly into correct cylinder bore, ensuring any directional marks face forward. Carefully guide rod onto crankshaft journal using rod bolt guide sleeves to prevent damaging journal.
10. 10

    Torque connecting rod bolts
    Install NEW connecting rod bolts into rod cap. Install cap in correct orientation matching previously made marks. Hand tighten bolts ensuring cap is fully seated. Using torque wrench, tighten both bolts to 45 Nm (33 lb-ft) in two steps (first to 22 Nm, then to final 45 Nm). Using torque angle gauge, rotate each bolt an additional 90 degrees in one smooth motion. Verify rotation is complete and equal on both bolts. Repeat process for remaining three connecting rods.
    ⚠️TTY bolts must receive both torque AND angle. Missing the angle portion will result in loose bolts and catastrophic engine failure.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
11. 11

    Verify crankshaft rotation
    After all connecting rods are installed and torqued, manually rotate crankshaft through two complete revolutions. Rotation should be smooth with even resistance. Any binding, tight spots, or unusual resistance indicates incorrect assembly. If any abnormality is felt, stop immediately and disassemble to diagnose issue.
    ⚠If crankshaft does not rotate smoothly, do not proceed. Disassemble and inspect for bearing installation errors, debris, or incorrect bearing clearances.
12. 12

    Install oil pan
    Install new oil pan gasket or apply RTV silicone sealant per factory service manual specifications. Install windage tray if equipped. Position oil pan and install all bolts hand tight. Following factory tightening sequence (typically starting at center and working outward in crisscross pattern), torque oil pan bolts to 12 Nm (9 lb-ft).
    ℹ️Oil pan bolt sequence is critical to prevent leaks and warping. Always follow specified pattern.
    Torque spec

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

    Reassemble engine components
    Reinstall cylinder head with new gasket following factory torque sequence and specifications. Reinstall timing chain with alignment marks correctly positioned. Install new timing chain cover gasket and cover. Install valve cover with new gasket. Install oil pump, intake manifold, exhaust manifold, fuel rail, and all sensors in reverse order of removal. Replace front and rear crankshaft seals.
    ⚠Timing chain alignment is critical. Verify all timing marks are correctly aligned before final assembly.
    Torque spec

    Gasket Bolts20 Nm (15 lb-ft)
14. 14

    Install engine in vehicle
    Carefully lower engine into engine bay using hoist. Align engine mounts and install mounting bolts. Reconnect transmission to engine. Reinstall all wiring harnesses, fuel lines, vacuum lines, coolant hoses, and exhaust connections. Reinstall radiator, AC condenser, and all previously removed components. Ensure all fasteners are torqued to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Fill fluids and perform initial startup
    Install new oil filter. Fill engine with 5.0 quarts of Hyundai Genuine 0W-20 engine oil. Install new crush washer on drain plug and torque to 35 Nm (26 lb-ft). Fill cooling system with 10 quarts of Hyundai/Kia Long Life Coolant. Reconnect battery. Before starting engine, crank with spark plugs removed to build oil pressure. Reinstall spark plugs and start engine. Monitor for oil pressure immediately - should register within 3 seconds. Check for leaks while engine idles.
    ⚠️If oil pressure warning light does not extinguish within 3 seconds of startup, shut down engine immediately and diagnose oil system issue.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Ensure all wiring harnesses are properly routed and secured away from hot exhaust components
2. Double-check that all fluid levels are correct before extended operation
3. Verify all cooling system hoses are properly secured with new clamps if originals were damaged
4. Confirm all vacuum lines are connected to prevent rough idle or check engine lights
5. Reinstall engine undercovers and front bumper cover

Verification

• Start engine and verify oil pressure light extinguishes within 3 seconds
• Allow engine to warm to operating temperature and verify cooling fan operation
• Check for any oil, coolant, or fuel leaks around all disturbed connections
• Listen for any unusual knocking, ticking, or grinding noises that could indicate bearing issues
• Perform test drive and monitor engine performance, oil pressure, and temperature
• After 50-100 miles of operation, re-check oil level and inspect for any new leaks
• Consider oil analysis after 500 miles to verify bearing break-in is progressing normally

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