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. Install the snap ring (A) in one side of the piston pin hole.
  
  Fig 1: Installing Snap Ring In One Side Of Piston Pin Hole
  Courtesy of KIA MOTORS AMERICA, INC.
2. Align the piston front mark and the connecting rod front mark.
  
  Fig 2: Aligning Piston Front Mark And Connecting Rod Front Mark
  Courtesy of KIA MOTORS AMERICA, INC.
3. Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod.
4. Install the snap ring (B) in the other side after inserting the piston pin.
  
  Fig 3: Inserting Piston Pin Into Piston Pin Hole And Small End Bore Of Connecting Rod
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.
  - Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.
  - Set the snap ring firmly so that the snap ring can contact with the whole groove of the piston pin hole.
  - Cutting face of snap ring must be located in the range of 45° to upper side.
  Fig 4: Checking Snap Ring Angle
  Courtesy of KIA MOTORS AMERICA, INC.
Assemble the piston rings.
1. Install the side rail and coil spring 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 5: Positioning Piston Ring Ends
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 6: Aligning Bearing Claw With Groove Of Connecting Rod And 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 7: Pressing Piston Rings With 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 torque-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 8: Liquid Gasket Applying Area 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 9: Installing Ladder Frame
  Courtesy of KIA MOTORS AMERICA, INC.
Assemble the other parts in the reverse order of disassembly.