Repair Procedures: Reassembly

WARNING: This page is about a different variant/trim than selected.

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.

Assemble the piston and the connecting rod.
1. Use a hydraulic press for installation.
2. The piston front mark (A) and the connecting rod front mark (A) must face the timing chain side of the engine.
  Pressing Load: 500 ~ 1, 500 kg (1, 102 ~ 3, 306 lb)
  
  Fig 1: Connecting Rod Front Mark
  Courtesy of KIA MOTORS AMERICA, INC.
Assemble the piston rings.
1. Install the oil ring coil spring and two 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.
  
  Fig 2: Positioning Piston Rings
  Courtesy of KIA MOTORS AMERICA, INC.
Assemble the connecting rod bearings.
1. Align the bearing (A) claw with the groove of the connecting rod and cap (B).
2. Install the bearings (A) in the connecting rod and cap (B).
  
  Fig 3: Installing Bearings In The Connecting Rod & Cap
  Courtesy of KIA MOTORS AMERICA, INC.
Insert the piston and connecting rod assemblies into the cylinder bores.
NOTE: Before installing the piston, apply a sufficient amount of engine oil to the ring grooves and cylinder bores.
1. Press the piston rings with a ring compressor and check that the rings are securely in place. Then insert the piston into the cylinder bore, and tap it in using the wooden handle of a hammer.
  
  Fig 4: Pressing Piston Rings Using Ring Compressor
  Courtesy of KIA MOTORS AMERICA, INC.
2. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
3. Install the rod caps with bearings, and tighten the bolts.
  Tightening Torque:
  
  17.7 ~ 21.8 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 88 ~ 92°
  
  NOTE: Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Check the side clearance between piston and connecting rod.
Install the ladder frame.
1. Apply the liquid gasket on the ladder frame.
  Bead Width: 2.5 ~ 3.5 mm (0.0984 ~ 0.1378 in)
  
  Fig 5: Applying Liquid Gasket On Ladder Frame
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Apply the sealant, THREE-BOND 1217H or LOCTITE 5900H on the ladder frame rail portion and install it within five minutes. If sealant is applied to cylinder block bottom position, the sealant position should be the same as that of the ladder frame rail.
  - Apply sealant along the inner line of the bolt holes.
2. Install the ladder frame (A).
  Tightening Torque:
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  Fig 6: Ladder Frame
  Courtesy of KIA MOTORS AMERICA, INC.
Assemble the other parts in the reverse order of disassembly.