Repair Procedures: Reassembly

1. Use a hydraulic press for installation.
2. The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
   Fig 1: Checking Difference Between Piston Pin Diameter And Connecting Rod Small End Diameter

   Courtesy of KIA MOTORS AMERICA, INC.

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.
   Fig 2: Identifying Piston Rings

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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 Bearings

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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

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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

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1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.

   Tightening torque 

   Main bearing cap bolt

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

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

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

   NOTE:

   • Always use new main bearing cap bolt.
   • If any of the bearing cap bolts in broken or deformed, replace it.
     Fig 7: Main Bearing Cap Bolts Tightening Sequence

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

   Fig 8: Installing Main Bearing Cap Bolts

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2. Check that the crankshaft turns smoothly.

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 

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

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

   Fig 9: Installing Connecting Rod Bearing Cap Bolts

   Courtesy 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 Piston

     Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque 

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68b-ft)

Fig 11: Identifying Oil Drain Cover

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Tightening torque 

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

Fig 13: Identifying Rear Oil Seal Case

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

Tightening torque 

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

Fig 16: Baffle Plate Bolts Tightening Sequence

Courtesy of KIA MOTORS AMERICA, INC.

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 : 2.5mm (0.1in.)

   Fig 17: Identifying Upper Oil Pan Liquid Sealant Apply Area

   Courtesy 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 to the inner threads of the bolt holes.
3. Install upper oil pan.

   Uniformly tighten the bolts in several passes.

   Tightening torque 

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

   Fig 18: Upper Oil Pan Bolts Tightening Sequence

   Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque 

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

Fig 19: Identifying Knock Sensor

Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque 

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