Replace compromised sport utility motors with this Hyundai Santa Fe G4JS Remanufactured Engine long block. Engineered for front-wheel drive crossovers, this 2.4L 4-Cylinder 16-Valve DOHC engine resolves chronic head gasket failure and bottom-end knock. A mandatory trade-off requires complete lubrication of internal balance shaft journals before turning the starter motor to protect soft bearing babbitt from friction.

Cast iron engine block carries casting mark G4JS or EF 2.4 stamped on the left side near cylinder number 1. The DOHC aluminum cylinder head houses dual camshafts and 16 valves. Crated envelope dimensions measure 36in length by 36in width by 36in height with a total dry weight of 265 lbs. Rotating parts feature a micro-polished nodular iron crankshaft, forged connecting rods, 2 balance shafts, and a 4.5-quart oil pan.

Key Features of Hyundai G4JS

Technicians buy Hyundai G4JS remanufactured engine assemblies to restore original compression and emissions compliance. This long block stops internal oil consumption while balancing crankshaft vibration across all 4 cylinders.

- Cast iron cylinder block decks receive precision CNC resurfacing to Ra 25 smoothness
- Diamond plateau cylinder honing creates cross-hatching that seats piston rings within 500 miles
- Micro-polished crankshaft journals hold 0.0003in TIR runout to safeguard connecting rod bearings
- Align-honed main bearing saddles maintain 0.0012in clearance to promote hydrodynamic oil film pressure
- Dual balance shaft assemblies receive line-bored bearings to cancel secondary engine vibration
- Multi-layer steel head gaskets prevent combustion leaks between the block and head
- Reconditioned 16-Valve cylinder heads feature valve seats cut to 0.001in concentricity for airflow

Dyno Load Precision Machining Tolerances

Automated dyno testing validates 138 HP at 5,500 RPM and 147 ft-lbs torque at 4,000 RPM under operational run conditions. Machine shop tolerances mandate crankshaft journal runout below 0.0003in TIR and connecting rod bearing oil clearances at 0.0012in. Plateau-honed cylinder walls produce compression between 175 PSI and 180 PSI across all 4 combustion chambers. Hot engine oil pressure measures 50 PSI at 3,000 RPM while regulated coolant operating temperatures maintain 192°F to verify water jacket flow integrity.

Vehicle Fitment Drivetrain Guide

This remanufactured long block fits 1999 to 2006 Hyundai Santa Fe, Hyundai Sonata, and Kia Optima models equipped with the 2.4L 2351cc DOHC 16-Valve L4 engine with block casting G4JS or EF 2.4. Compatible with front-wheel drive and all-wheel drive drivetrains paired with 4-Speed Automatic or 5-Speed Manual transaxles. Fitment warning: this unit does not fit 2.4L Theta G4KC platforms, 2.7L Delta V6 vehicles, or Mitsubishi models with alternate starter bolt positions.

Installation Protocol Service Schedules

Verify balance shaft belt timing alignment and check oil pump drive sprocket orientation before spinning the crankshaft. Flush the external oil cooler and heater core to remove residual metal flakes from past engine failures. Never install this non-turbo long block into custom turbo setups exceeding 5 PSI of boost without low-compression pistons and revised fuel mapping.

- Fill engine crankcase with 4.5 quarts of SAE 5W-30 break-in oil before running the starter
- Drain break-in motor oil and replace the spin-on filter after completing the first 500 miles
- Perform recurring synthetic blend oil and filter changes every 3,000 miles or 5,000 miles

Warranty Terms Core Return Policy

Every remanufactured engine includes our comprehensive 3-Year Unlimited-Mile parts warranty for retail and fleet installations. Our freight dispatch arranges prepaid return tags for your rebuildable core block within an authorized 30-day window. Each crate holds the long block assembly, oil pan, front timing cover, and installation manual.