Complete replacement of the short block assembly, including removal of the cylinder head and all internal engine components, installation of new block, and reassembly of all engine systems.

Warnings

Tools required

Parts

• Short block assembly (complete) × 1 — Use OEM specification
• Head gasket set × 1 — Use OEM specification
• Timing chain kit (chain, guides, tensioner) × 1 — Use OEM specification
• Oil pump × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• Crankshaft rear seal × 1 — Use OEM specification
• Oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant × 2 — Hyundai/Kia Long Life Green
• Main bearing set × 1 — Use OEM specification
• Rod bearing set × 1 — Use OEM specification
• Piston ring set (if not included with short block) × 1 — Use OEM specification
• All engine mount hardware × 1 — Use OEM specification
• Miscellaneous bolts and fasteners × 1 — Replace all TTY bolts

Fluids

• Kia Genuine 5W-20 engine oil — 4.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 7.5 qt

Preparation

1. Disconnect negative battery cable and isolate
2. Drain engine oil completely and remove oil filter
3. Drain cooling system completely into appropriate container
4. Remove hood and store safely to provide workspace clearance
5. Raise vehicle on lift or support securely on jack stands at all four corners
6. Remove engine splash shields and underbody panels
7. Remove front bumper cover for radiator and accessory access
8. Label and photograph all electrical connectors, vacuum lines, and hose routing before disconnection
9. Relieve fuel system pressure by removing fuel pump fuse and cranking engine
10. Prepare clean assembly area with lint-free cloths for component storage

Procedure

1. 1

   Remove intake and exhaust systems
   Disconnect throttle body, remove air intake assembly completely. Disconnect all fuel lines using proper quick-disconnect tools. Remove fuel rail and injectors as assembly, cap all openings immediately. Unbolt exhaust manifold from cylinder head and disconnect from downpipe. Remove exhaust manifold and gasket.
2. 2

   Remove accessory drive system and front engine components
   Remove serpentine belt. Remove alternator, A/C compressor (support without disconnecting lines), and power steering pump (support without disconnecting lines). Remove all accessory brackets. Using harmonic balancer puller, remove crankshaft pulley. This requires holding crankshaft to prevent rotation.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing cover and timing components
   Remove all timing cover bolts following reverse of tightening sequence. Remove timing cover carefully to avoid damaging sealing surfaces. Mark timing chain alignment before removal. Remove timing chain tensioner, guides, and timing chain. Inspect timing chain sprockets for wear.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
4. 4

   Remove cylinder head assembly
   Disconnect all remaining electrical connectors from cylinder head including camshaft sensors, VVT solenoids. Remove valve cover. Mark and remove camshaft caps in reverse order of installation sequence. Remove camshafts and store safely. Remove cylinder head bolts in reverse of torque sequence (outside to inside pattern). Lift cylinder head off block, remove head gasket. Cover cylinder bores immediately with clean shop towels to prevent debris entry.
   Torque spec

   Gasket Bolts19 Nm (14 lb-ft)
5. 5

   Separate transmission from engine
   Support transmission with transmission jack or appropriate support. Remove all transmission-to-engine bolts. If manual transmission, remove clutch pressure plate and disc using flywheel holding tool. For automatic, mark torque converter position. Carefully separate transmission from engine, ensuring torque converter remains with transmission. Remove flywheel or flexplate using flywheel holding tool, removing bolts in star pattern.
   ⚠Transmission must be properly supported before removing mounting bolts to prevent falling and causing injury or damage.
   Torque spec

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

   Flywheel Bolts95 Nm (70 lb-ft)
6. 6

   Remove engine from vehicle
   Attach engine hoist with load leveler to engine lifting points. Remove engine mount bolts from all mounts (front, rear, and side mounts). Carefully lift engine while checking for any remaining connections. Once clear, move engine to clean work area on engine stand or suitable support.
   Torque spec

   Mounting Bolts45 Nm (33 lb-ft)
7. 7

   Disassemble remaining engine components
   Remove oil pan bolts and oil pan. Remove oil pickup tube. Remove oil pump bolts and oil pump assembly. Remove rear main seal housing. Carefully rotate engine to access oil filter housing and all external sensors. Remove all sensors and mark locations.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)

   Sensor Bolts10 Nm (8 lb-ft)
8. 8

   Prepare new short block for installation
   Thoroughly inspect new short block for shipping damage or debris. Verify all main bearing caps are properly installed and torqued. Check that cylinder bores are properly honed and free of debris. Rotate crankshaft to ensure free movement. Apply assembly lube to all bearing surfaces, cylinder walls, and piston skirts. Install piston rings if not pre-installed, ensuring proper orientation and end gap positioning.
   ⚠Verify bearing clearances even on new short block using Plastigage. Clearances should be 0.0008-0.0020 inches for mains, 0.0011-0.0018 inches for rods.
9. 9

   Install oil pump and lubrication system components
   Install new crankshaft rear seal using seal driver, ensuring proper depth and alignment. Install rear seal housing with new gasket. Pack oil pump with petroleum jelly to prime. Install oil pump with new gasket, torquing bolts in crisscross pattern. Install oil pickup tube with new O-ring. Clean oil pan thoroughly and install with new gasket using thin bead of RTV at front and rear corners.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)
10. 10

    Install engine and connect to transmission
    Using engine hoist, carefully lower engine into engine bay, aligning with transmission and engine mounts. Install all engine mount bolts hand-tight first, then torque to specification. Align transmission to engine, ensuring proper torque converter or clutch alignment. Install all transmission-to-engine bolts and torque in star pattern. Install flywheel or flexplate with new bolts using flywheel holder, torquing in star pattern.
    ⚠Verify torque converter is fully seated before mating transmission to engine. Should be recessed approximately 1/2 inch from bellhousing face.
    Torque spec

    Mounting Bolts45 Nm (33 lb-ft)

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

    Flywheel Bolts95 Nm (70 lb-ft)
11. 11

    Install timing components and front cover
    Install crankshaft front seal using seal driver. Install new timing chain guides and tensioner in released position. Install timing chain, aligning timing marks on crankshaft and camshaft sprockets precisely. Install timing chain tensioner and release. Verify timing alignment three times by rotating crankshaft two complete revolutions. Clean timing cover mating surfaces and install new gasket. Install timing cover following proper bolt sequence with 8mm bolts. Install crankshaft pulley using new bolt if TTY specification applies.
    ⚠️Incorrect timing chain installation will cause severe engine damage immediately upon startup. Triple-check all timing marks before proceeding.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
12. 12

    Install cylinder head assembly
    Clean cylinder head and block mating surfaces with gasket scraper and brake cleaner. Install new head gasket with proper orientation (TOP marking facing up). Carefully lower cylinder head onto block, aligning dowel pins. Install new head bolts (TTY) hand-tight. Torque head bolts following manufacturer's sequence and specifications: typically 22 ft-lbs, then 90 degrees, then additional 90 degrees. Install camshafts with proper timing alignment. Install camshaft caps in numbered sequence. Install valve cover with new gasket.
    ⚠️Head bolts are TTY and must be replaced. Follow exact torque sequence from center outward. Improper torquing will cause head gasket failure.
    Torque spec

    Gasket Bolts19 Nm (14 lb-ft)
13. 13

    Reinstall accessory components and systems
    Install all accessory brackets with proper fasteners. Reinstall alternator, A/C compressor, and power steering pump to brackets. Install serpentine belt following proper routing diagram. Reinstall exhaust manifold with new gasket and new nuts. Connect exhaust system. Install intake manifold with new gaskets. Reconnect fuel rail and injectors. Install throttle body and air intake system.
    Torque spec

    Mounting Bolts45 Nm (33 lb-ft)
14. 14

    Reconnect all electrical and fluid systems
    Reconnect all electrical connectors using labels and photos from disassembly. Reconnect all vacuum lines and coolant hoses. Install new oil filter. Install oil drain plug with new crush washer. Reinstall all sensors. Reinstall front bumper cover. Reinstall splash shields. Lower vehicle.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

    Sensor Bolts10 Nm (8 lb-ft)
15. 15

    Fill fluids and perform initial startup
    Fill crankcase with 4.5 quarts of Kia Genuine 5W-20 engine oil. Fill cooling system with 7.5 quarts of Hyundai/Kia Long Life Green coolant, bleeding air from system. Reconnect battery. Turn ignition to ON position without starting to prime fuel system (repeat 3-4 times). Disable ignition and crank engine for 10 seconds to build oil pressure. Start engine and monitor for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature while monitoring closely.
    ⚠️Stop engine immediately if oil pressure warning light remains on, unusual noises occur, or leaks are observed. Do not continue running engine.
    ℹ️Initial startup may produce light smoke or odors from assembly lubricants and new gaskets burning off. This is normal if brief.

Reassembly

1. Reinstall hood and align properly
2. Perform complete cooling system pressure test to verify no leaks
3. Change engine oil and filter after initial 500 miles of break-in
4. Retorque cylinder head bolts after first heat cycle if manufacturer specifies (check service manual)
5. Monitor oil pressure, coolant temperature, and engine operation closely during first 100 miles

Verification

• Verify no oil leaks from pan, timing cover, valve cover, or oil filter after test drive
• Verify no coolant leaks from any connections or gaskets
• Confirm oil pressure gauge shows normal pressure at idle and under acceleration
• Verify engine operates smoothly with no misfires, rough idle, or unusual noises
• Scan for diagnostic trouble codes and verify no engine-related codes present
• Verify all accessories (alternator, A/C, power steering) function properly
• Check engine oil level and condition after test drive, look for coolant contamination
• Verify proper engine temperature operation with no overheating

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