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Engine Block: Reassembly

NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  • Replace all gaskets, O-rings and oil seals with new parts.
  1. Assemble piston and connecting rod.
    1. Use a hydraulic press for installation.
    2. The piston front mark and the connecting rod front mark must face the timing chain end of the engine.
    Fig 1: Identifying Piston Front Mark And Connecting Rod Front Mark
    G04803628Courtesy of KIA MOTORS AMERICA, INC.
  2. Install piston rings.
    1. Install the oil ring spacer and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
    3. Position the piston rings so that the ring ends are as shown in Fig 2.
    Fig 2: Positioning Piston Rings
    G04803629Courtesy of KIA MOTORS AMERICA, INC.
  3. Install connecting rod bearings.
    1. Align the bearing claw with the groove of the connecting rod or connecting rod cap.
    2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
    Fig 3: Identifying Bearing And Connecting Rod Cap
    G04803630Courtesy of KIA MOTORS AMERICA, INC.
  4. Install main bearings.
    NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not.
    1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings.
    2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings (A).
    Fig 4: Identifying Lower Bearings
    G04883089Courtesy of KIA MOTORS AMERICA, INC.
  5. Install thrust bearings.

    Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

    Fig 5: Identifying Thrust Bearings
    G04803632Courtesy of KIA MOTORS AMERICA, INC.
  6. Place crankshaft on the cylinder block.
    Fig 6: Identifying Crankshaft
    G04883066Courtesy of KIA MOTORS AMERICA, INC.
  7. Place main bearing caps on cylinder block.
  8. Install main bearing cap bolts.
    1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown in illustration.

      Tightening torque 

      Main bearing cap bolt

      49.00 N.m (5.0 kgf.m, 36.16 lb-ft) + 90° (1-8)

      19.60 N.m (2.0 kgf.m, 14.46 lb-ft) + 120° (9-16)

      29.40-31.36 N.m (3.0-3.2 kgf.m, 21.70-23.14 lb-ft) (17-22)

      NOTE:
      • Always use new main bearing cap bolt.
      • If any of the bearing cap bolts is broken or deformed, replace it.
      Fig 7: Identifying Bearing Cap Bolts Tightening Sequence
      G04883092Courtesy of KIA MOTORS AMERICA, INC.

      Use SST (09221-4A000), install main bearing cap bolts.

      Fig 8: Identifying SST (09221-4A000)
      G04883093Courtesy of KIA MOTORS AMERICA, INC.
    2. Check that the crankshaft turns smoothly.
  9. Check crankshaft end play. Refer to CONNECTING ROD AND CRANKSHAFT .
  10. Install piston and connecting rod assemblies.
    NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
    1. Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
    2. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
    3. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.

    Tightening torque 

    17.7-21.6 N.m (1.8-2.2 kgf.m, 13.0-15.9 lb-ft) + 88-92°

    Use SST (09221-4A000), install connecting rod bearing cap bolts.

    Fig 9: Identifying SST (09221-4A000)
    G04883094Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Always use new connecting rod bearing cap bolt.
    • Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
    Fig 10: Installing Pistons
    G04803635Courtesy of KIA MOTORS AMERICA, INC.
  11. Check the connecting rod end play. Refer to CONNECTING ROD AND CRANKSHAFT .
  12. Install oil drain cover.

    Tightening torque 

    9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)

    Fig 11: Locating Oil Drain Cover
    G04883065Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Ensure the sealing face is clean before assembling two parts.
    • Remove harmful foreign matters on the sealing face before applying sealant
    • Before assembling oil drain cover, the liquid sealant TB1217H should be applied oil drain cover.
    • The part must be assembled within 5 minutes after sealant was applied.
    • Apply sealant to the inner threads of the bolt holes.
    Fig 12: Identifying Sealant Area On Oil Drain Cover
    G04883097Courtesy of KIA MOTORS AMERICA, INC.
  13. Install rear oil seal case.

    Tightening torque 

    9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.67 lb-ft)

    Fig 13: Locating Rear Oil Seal Case
    G04883064Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Make clean the sealing face before assembling two parts.
    • Remove harmful foreign matters on the sealing face before applying sealant
    • Before assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case.
    • The part must be assembled within 5 minutes after sealant was applied.
    • Apply sealant to the inner threads of the bolt holes.
    Fig 14: Identifying Sealant Area On Rear Oil Seal Case
    G04883099Courtesy of KIA MOTORS AMERICA, INC.
  14. Using SST (09231-3C200, 09231-H1100), install rear oil seal.
    Fig 15: Identifying SST (09231-3C200, 09231-H1100)
    G04883100Courtesy of KIA MOTORS AMERICA, INC.
  15. Install baffle plate.

    Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in illustration.

    Tightening torque 

    9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)

    Fig 16: Identifying Baffle Plate Bolts Tightening Sequence
    G04883101Courtesy of KIA MOTORS AMERICA, INC.
  16. Install upper oil pan.
    1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
    2. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. The part must be assembled within 5 minutes after the sealant was applied.

      Bead width: 2.5 mm (0.1 in.)

      Fig 17: Identifying Sealant Area On Upper Oil Pan
      G04883102Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • Ensure the sealing face is clean before assembling two parts.
      • Remove harmful foreign matters on the sealing face before applying sealant
      • When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
      • To prevent leakage of oil, apply sealant gasket of the inner threads of the bolt holes.
    3. Install upper oil pan.

      Uniformly tighten the bolts in several passes.

    Tightening torque 

    9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)

    Fig 18: Identifying Upper Oil Pan Bolts Tightening Sequence
    G04883103Courtesy of KIA MOTORS AMERICA, INC.
  17. Install knock sensor.

    Tightening torque 

    15.68-23.52 N.m (1.6-2.4 kgf.m, 11.57-17.36 lb-ft)

    Fig 19: Locating Knock Sensor
    G04883061Courtesy of KIA MOTORS AMERICA, INC.
  18. Install drive plate.

    Tightening torque 

    71.54-75.46 N.m (7.3-7.7 kgf.m, 52.80-55.69 lb-ft)

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