Repair Procedures: Disassembly

Remove drive plate.
Remove knock sensor (A).

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

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

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

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

Fig 5: Identifying Oil Drain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Check the connecting rod end play.
Check the connecting rod cap oil clearance.
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.
Check the crankshaft end play.
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 pin.
Try to move the piston back and forth on the piston pin. 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 ~ 1400kg (1764 ~ 3086lb)