Engine Block: Disassembly

Remove drive plate.
Remove knock sensor (A).

Fig 1: Locating Knock Sensor
Courtesy of KIA MOTORS AMERICA, INC.
Remove upper oil pan (A).

Fig 2: Locating Upper Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
Remove baffle plate (A).

Fig 3: Locating Baffle Plate
Courtesy of KIA MOTORS AMERICA, INC.
Remove rear oil seal case (A).

Fig 4: Locating Rear Oil Seal Case
Courtesy of KIA MOTORS AMERICA, INC.
Remove oil drain cover (A).

Fig 5: Locating Oil Drain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Check the connecting rod end play. Refer to CONNECTING ROD AND CRANKSHAFT .
Check the connecting rod cap oil clearance. Refer to CONNECTING ROD AND CRANKSHAFT .
Remove piston and connecting rod assemblies.
1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
NOTE:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.
Remove crankshaft main bearing cap and check oil clearance. Refer to CONNECTING ROD AND CRANKSHAFT .
Check the crankshaft end play. Refer to PISTON AND RINGS .
Lift the crankshaft (A) out of engine, being careful not to damage journals.

Fig 6: Identifying Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Arrange the main bearings and thrust bearings in the correct order.
Check fit between piston and piston p in.
Try to move the piston back and forth on the piston p in. If any movement is felt, replace piston and piston pin as a set.
Remove piston rings.
1. Using a piston ring expender, remove the 2 compression rings.
2. Remove 2 side rails and the spacer by hand.
NOTE: Arrange the piston rings in the correct order only.
Disconnect connecting rod from piston.
Using a press, remove the piston pin from piston. (Press-in load: 800-1400 kg (1764-3086 lbs.)