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Home >> Kia >> 2021 >> Forte EX >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block - 2.0L >> Piston And Connecting Rod >> Repair Procedures >> Disassembly
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Repair Procedures: Disassembly

Engine removal is required for this procedure.

NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
  • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Information 

  1. Remove the engine assembly from the vehicle.

    (Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")

  2. Remove the manual transaxle assembly from the engine assembly.

    (Refer to Manual Transaxle System - "MANUAL TRANSAXLE ")

    Remove the intelligent variable transmission assembly from the engine assembly.

    (Refer to Intelligent Variable Transmission (IVT) System - "INTELLIGENT VARIABLE TRANSMISSION (IVT) ")

  3. Intelligent variable transmission: Remove the drive plate

    (Refer to Cylinder Block - "DRIVE PLATE ")

    Manual transaxle: Remove the flywheel.

    (Refer to Cylinder Block - "FLY WHEEL ")

  4. Remove the rear oil seal.

    (Refer to Cylinder Block - "REAR OIL SEAL ")

  5. Install the engine to engine stand for disassembly.
  6. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  7. Remove the water pump assembly.

    (Refer to Cooling System - "WATER PUMP ")

  8. Remove the water inlet fitting and the electric thermostat (ECT).

    (Refer to Cooling System - "ELECTRIC THERMOSTAT (ECT) ")

  9. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  10. Remove the A/C compressor.

    (Refer to Heating, Ventilation Air conditioning - "COMPRESSOR ")

  11. Remove the exhaust manifold.

    (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

  12. Remove the cylinder head assembly.

    (Refer to Cylinder Head Assembly - "CYLINDER HEAD ")

  13. Remove the oil filter.

    (Refer to Lubrication System - "ENGINE OIL ")

  14. Remove the oil screen.

    (Refer to Lubrication System - "OIL PAN ")

  15. Check the connecting rod side clearance.
  16. Check the connecting rod bearing cap oil clearance.
  17. Remove the piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod bearing caps (A).
      G13306581Courtesy of KIA MOTORS AMERICA, INC.

      Information 

      Mark the connecting rod, and caps to be able to reassemble in the original position and direction.

    3. Push the piston and connecting rod assembly with upper bearing through the top of the cylinder block.

      Information 

      • Keep the connecting rod and cap with their bearings assembled together.
      • Arrange the piston and connecting rod assemblies in the correct order.
      • Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
  18. Check fit between piston and piston pin.

    Try to move the piston back and forth on the piston pin.

    If any movement is felt, replace the piston and pin as a set.

  19. Remove piston rings.
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove 2 side rails and the oil ring by hand.

      Information 

      Arrange the piston rings in the correct order.

  20. Disassemble the connecting rod from the piston.
    1. Remove the snap ring (A) from the piston.
    2. Remove the piston pin (B) from piston.
    3. Disassemble the piston (C) and connecting rod (D).
      G13306582Courtesy of KIA MOTORS AMERICA, INC.
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