Complete replacement of the short block assembly on a 2016-2024 Hyundai Tucson 2.5L I4 AWD engine, including removal of cylinder head and transfer of all internal components to the new short block.

Warnings

Tools required

Parts

• Short block assembly (complete with pistons, crankshaft, camshafts) × 1 — Use OEM specification
• Head gasket set (includes head gasket and valve cover gasket) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioners) × 1 — Use OEM specification
• Main bearing set × 1 — Use OEM specification
• Rod bearing set × 1 — Use OEM specification
• Oil pump × 1 — Use OEM specification
• Water pump × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant (Hyundai approved) × 1 — Use OEM specification
• Engine coolant × 2 — Hyundai/Kia Long Life Green
• All engine mounting bolts (TTY bolts) × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification

Fluids

• Hyundai Genuine 0W-20 Engine Oil — 5 qt
• Hyundai/Kia Long Life Coolant (Green) — 10 qt
• Hyundai SP-IV-M ATF — 1 qt
• 75W-90 GL-5 Gear Oil (Front Diff) — 1.5 qt
• Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and isolate terminal - wait 15 minutes for airbag system discharge
3. Remove engine cover and any plastic shrouding from engine bay
4. Drain engine oil completely and remove oil filter
5. Drain engine coolant from radiator petcock and engine block drain plugs into appropriate containers
6. Remove front bumper cover for access to radiator and cooling system components
7. Remove hood assembly (mark hinge positions for reinstallation alignment)
8. Raise vehicle on lift or jack stands at all four corners ensuring stability
9. Remove front wheels and engine under covers/splash shields
10. Remove air intake system from air filter box to throttle body
11. Label and photograph all electrical connectors, vacuum lines, and coolant hoses before disconnection
12. Recover refrigerant from A/C system using approved equipment and disconnect A/C lines from compressor
13. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
14. Disconnect fuel lines at fuel rail using quick-disconnect tool
15. Position engine hoist with load leveler and attach lifting chains to engine lift points
16. Support transmission with transmission jack from underneath vehicle

Procedure

1. 1

   Remove exhaust system and driveline components
   Disconnect exhaust system at manifold flange and catalytic converter. Support and remove front driveshaft from transfer case (mark alignment). Disconnect rear driveshaft from transfer case output flange (mark alignment). Remove front axle halfshafts from front differential - support outer CV joints to prevent damage. Cap all open differential and transfer case ports to prevent fluid loss and contamination.
2. 2

   Disconnect all engine external connections
   Disconnect all remaining electrical connectors including alternator, starter, engine sensors (cam position, crank position, knock sensors, oil pressure, coolant temp). Disconnect engine wiring harness from firewall connectors. Remove accessory drive belt and serpentine belt. Disconnect power steering pressure line (if equipped with hydraulic - this model uses electric). Disconnect all coolant hoses from engine including radiator hoses, heater hoses, and bypass hoses. Remove throttle body connections and intake manifold vacuum lines.
3. 3

   Separate transmission from engine
   Remove transmission bellhousing inspection cover. Mark torque converter to flexplate relationship. Remove torque converter to flexplate bolts by rotating crankshaft to access each bolt. Support transmission securely with transmission jack. Remove all transmission-to-engine mounting bolts. Carefully separate transmission from engine ensuring torque converter remains with transmission. Pull engine forward away from transmission input shaft.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
4. 4

   Remove engine from vehicle
   Remove engine mounting bolts from both left and right engine mounts and front mount. Verify all connections are disconnected (electrical, fuel, coolant, vacuum, exhaust). Slowly lift engine using hoist while guiding clear of surrounding components and firewall. Once clear of engine bay, lower engine onto engine stand and secure using 4 mounting points. Remove all accessories: alternator, A/C compressor, power steering pump, starter motor, and any remaining sensors or brackets.
   Torque spec

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

   Remove timing components and front covers
   Position engine at TDC on cylinder #1 (align timing marks). Use flywheel holding tool to prevent crankshaft rotation. Use impact wrench to remove crankshaft pulley bolt (reverse thread awareness - standard right-hand thread). Remove crankshaft pulley/harmonic balancer using puller if necessary. Remove timing chain cover bolts in reverse of tightening sequence. Carefully pry timing cover from block - clean all RTV residue. Remove timing chain tensioner, guides, and timing chain. Mark chain orientation if reusing. Remove both camshaft sprockets.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

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

   Remove cylinder head assembly
   Remove valve cover by removing cover bolts in sequence. Remove intake and exhaust manifolds with gaskets. Remove cylinder head bolts in reverse of tightening sequence (start from outside working inward in multiple passes). Lift cylinder head from block - may require gentle prying at designated pry points (never pry on gasket surface). Place cylinder head on clean work surface. Cover cylinder bores with clean shop towels to prevent debris entry. Clean all head gasket material from block deck surface using plastic scraper - do not gouge aluminum.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)

   Gasket Bolts20 Nm (15 lb-ft)
7. 7

   Remove oil pan and oil pump
   Invert engine on stand for access to oil pan. Remove all oil pan bolts and carefully separate pan from block using plastic pry tool - do not damage sealing surfaces. Clean all gasket material and RTV from pan and block surfaces. Remove oil pump mounting bolts and extract oil pump assembly with pickup tube. Remove windage tray or baffles if equipped. Inspect oil pump drive chain or gears for wear.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
8. 8

   Remove pistons and connecting rods
   Rotate crankshaft to position connecting rod at bottom dead center. Mark each connecting rod and cap with cylinder number and orientation using permanent marker or stamps. Check rod bearing cap orientation marks from factory. Remove connecting rod bolts from rod cap. Carefully separate rod cap and bearing. Push piston and rod assembly up and out through top of cylinder bore. Keep rod caps with their respective rods. Remove upper rod bearing from rod. Repeat for all 4 cylinders. Store piston assemblies in order on clean work surface.
   ⚠Connecting rod bolts are TTY (Torque-To-Yield) and must be replaced - never reuse old rod bolts
   Torque spec

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

   Remove crankshaft and main bearings
   Mark all main bearing caps with position number and orientation direction if not already marked from factory. Remove main bearing cap bolts in sequence from outer caps working toward center. Carefully lift and remove each main bearing cap keeping them in order. Lift crankshaft straight up out of engine block. Remove upper main bearing shells from block saddles. Remove lower main bearing shells from caps. Inspect crankshaft journals and bearing surfaces for scoring or damage. Clean all bearing surfaces thoroughly with brake parts cleaner.
   ⚠Main bearing cap bolts are TTY (Torque-To-Yield) and must be replaced with new OEM bolts - never reuse
   Torque spec

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

    Prepare and inspect new short block
    Unpack new short block and verify it matches original engine specifications. Remove all shipping protective covers and plugs. Thoroughly clean all machined surfaces with brake parts cleaner. Inspect cylinder bores for any shipping damage or contamination. Verify all core plugs (freeze plugs) are properly installed. Measure main bearing journals and rod journals with micrometer to verify specifications. Install new main bearings into block saddles ensuring oil holes align and bearing tabs seat properly in notches. Lubricate bearings with assembly lube or clean engine oil.
11. 11

    Install crankshaft with main bearings
    Apply assembly lubricant to all main bearing surfaces. Carefully lower crankshaft into block main saddles ensuring journals seat properly on bearings. Install lower main bearing shells into main caps with tabs properly seated. Apply assembly lubricant to lower bearing surfaces. Install main bearing caps in correct positions and orientations - verify match marks align. Install NEW main bearing cap bolts (TTY bolts - do not reuse old bolts). Hand tighten all main cap bolts. Torque main bearing cap bolts to 75 Nm (55 lb-ft) in sequence from center outward. Follow with additional torque angle as specified (typically 90 degrees additional rotation). Verify crankshaft rotates freely by hand with no binding.
    ⚠Must use NEW main bearing cap bolts - TTY bolts cannot be reused or engine failure will result
    ⚠Follow proper tightening sequence from center main bearing outward to prevent crankshaft misalignment
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Install pistons and connecting rods
    Install new rod bearings into connecting rods and rod caps - ensure oil holes align and tabs seat in notches. Apply assembly lubricant to rod bearings and piston skirts. Install piston ring compressor around piston rings. Position piston/rod assembly with mark facing front of engine. Insert rod/piston assembly into correct cylinder bore from top. Gently tap piston crown with wooden hammer handle while guiding rod journal onto crankshaft journal. Install rod cap with NEW rod bolts in correct orientation. Hand tighten rod bolts. Torque rod bolts to 45 Nm (33 lb-ft) then follow with additional angle rotation per specification (typically 60-90 degrees). Verify rod has proper side clearance and rotates freely on journal. Repeat for all cylinders. Check crankshaft rotation after each piston installation.
    ⚠Use NEW connecting rod bolts only - these are TTY and cannot be reused
    ⚠Ensure piston orientation marks face front of engine and ring gaps are properly staggered
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
13. 13

    Install oil pump and oil pan
    Install new oil pump with new gasket or O-ring. Ensure pump drive gear or chain properly engages with crankshaft. Torque oil pump mounting bolts to 12 Nm (9 lb-ft). Clean oil pan and block sealing surfaces completely - must be free of all old RTV and oil residue. Apply continuous 3mm bead of Hyundai-approved RTV silicone to oil pan rail - circle all bolt holes on inside. Install oil pan within 5 minutes of RTV application before it skins over. Install oil pan bolts and torque to 12 Nm (9 lb-ft) in spiral pattern from center outward. Allow RTV to cure for minimum 1 hour before adding oil. Install new oil drain plug crush washer and install drain plug - torque to 35 Nm (26 lb-ft).
    ⚠Oil pan must be installed within 5 minutes of RTV application - work quickly but carefully
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
14. 14

    Install timing components and covers
    Clean timing cover and engine block mating surfaces thoroughly. Apply thin bead of RTV to timing cover gasket areas per factory specification. Install new timing cover gasket. Position timing cover and install bolts hand tight. Torque timing cover 8mm bolts to 25 Nm (18 lb-ft) in proper sequence. Install crankshaft sprocket onto crankshaft ensuring keyway aligns. Install timing chain with colored links aligned to marks on cam and crank sprockets. Install camshaft sprockets with timing marks aligned to TDC position. Install timing chain guides and tensioner - release tensioner to apply proper chain tension. Rotate crankshaft 2 complete revolutions and verify timing marks realign at TDC. Install crankshaft pulley and new pulley bolt - torque to 180 Nm (133 lb-ft) using impact wrench or torque multiplier.
    ⚠Verify timing alignment at TDC before final assembly - incorrect timing will cause engine damage
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
15. 15

    Install cylinder head and complete engine assembly
    Ensure block deck surface is perfectly clean and dry. Install new head gasket with orientation marks facing upward - do not use any sealant on head gasket. Verify dowel pins are in place. Carefully lower cylinder head onto block ensuring dowel pins engage holes in head. Install NEW cylinder head bolts (if TTY type). Torque head bolts in proper sequence using multiple steps as specified by Hyundai (typically 3-4 progressive torque steps plus final angle). Install intake and exhaust manifolds with new gaskets. Install valve cover with new gasket - torque cover bolts to 16 Nm (12 lb-ft). Reinstall all accessories (alternator, A/C compressor, starter, sensors). Mount engine to engine hoist and remove from engine stand.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)

Reassembly

1. Installation is reverse of removal with the following critical points
2. Guide engine into engine bay carefully avoiding damage to radiator, A/C lines, and firewall components
3. Align engine mounts and install mounting bolts - torque to 27 Nm (20 lb-ft) and 47 Nm (35 lb-ft) per specification for different mount locations
4. Before mating transmission, verify torque converter is fully seated in transmission (should feel 2-3 distinct clicks when installing)
5. Rotate crankshaft to align flexplate to torque converter bolt holes
6. Torque transmission-to-engine bolts to 55 Nm (41 lb-ft)
7. Install driveshafts aligning marks made during disassembly to prevent driveline vibration
8. Reinstall front halfshafts with new circlips - ensure they click into differential
9. Reconnect all electrical connectors, fuel lines, coolant hoses, and vacuum lines per photos taken during disassembly
10. Install new oil filter and fill engine with 5 quarts Hyundai Genuine 0W-20 oil
11. Refill cooling system with 10 quarts Hyundai/Kia Long Life Coolant (Green) - bleed air from system using bleeder screw
12. Check and refill transfer case fluid (2.5 quarts) and front differential (1.5 quarts) with 75W-90 GL-5 gear oil
13. Reconnect A/C lines with new O-rings and evacuate/recharge system to specification
14. Double-check all fasteners are torqued to specification and no tools or parts are left in engine bay

Verification

• Reconnect battery and verify no warning lights appear on instrument cluster before starting
• Prime oil system by removing fuel pump relay and cranking engine for 10 seconds intervals until oil pressure builds
• Perform initial start and immediately verify oil pressure gauge shows pressure within 5 seconds
• Allow engine to idle and carefully inspect for any oil, coolant, or fuel leaks around all connection points
• Monitor coolant temperature gauge and verify cooling fans cycle properly - watch for overheating
• Listen for any abnormal engine noises (knocking, rattling, ticking beyond normal valve train noise)
• After engine reaches operating temperature, shut down and allow to cool for 30 minutes
• Recheck all fluid levels (oil, coolant, transmission, differentials, transfer case) and top off as needed
• Check for any leaks after cool down period - tighten any connections as needed
• Perform test drive monitoring engine performance, temperature, and oil pressure under load
• Check for proper AWD engagement and smooth operation without vibrations
• After 500 miles, change engine oil and filter again (break-in oil change)
• Recheck all critical torque specifications after first 500 miles of operation

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