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Home › Kia › 2002 › Rio Base, Standard › Repair and Diagnosis › Engine Mechanical › Lubrication System › 1.5L 4-Cylinder Engine › Main Moving System › Piston & Connecting Rod Assembly › Reassembly

Piston & Connecting Rod Assembly: Reassembly

  1. Select the piston which has the size mark which is identical with the size mark of the corresponding cylinder.
    • Cylinder size mark marking location
    • Piston size mark marking location
    Fig 1: Identifying Cylinder Size Mark Location
    G00325913Courtesy of KIA MOTORS AMERICA, INC.
    Fig 2: Identifying Piston Size Mark Location
    G00325914Courtesy of KIA MOTORS AMERICA, INC.
    Fig 3: Piston Outer Diameter & Cylinder Bore Inner Diameter Chart
    G00325915Courtesy of KIA MOTORS AMERICA, INC.
  2. Insert connecting rod into piston and slide piston pin through piston and connecting rod.
    NOTE: Verify that piston and rod are assembled in same direction as they were prior to disassembly.
  3. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
  4. Install three piece oil ring onto piston.
    1. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
    2. Install expander onto piston so that expander ends face upward.
    3. Install lower oil ring onto piston. Ring may be installed with either face upward.
    4. Install upper oil ring onto piston. Ring may be installed with either face upward.
    Fig 4: Installing Oil Ring
    G00325916Courtesy of KIA MOTORS AMERICA, INC.
  5. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
    Fig 5: Illustrating Oil Ring Position
    G00325917Courtesy of KIA MOTORS AMERICA, INC.
  6. Use a ring expander and install second ring.
  7. Use a ring expander and install top ring.
    Fig 6: Identifying Top & Second Ring Direction
    G00325918Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Top ring and second ring should be installed with "R" or "Y" mark facing up.
  8. Align piston ring gaps as shown.
    Fig 7: Aligning Piston Ring Gaps
    G00325919Courtesy of KIA MOTORS AMERICA, INC.
  9. Install a bearing into connecting rod.
  10. Place rubber sleeves on connecting rod bolts to protect crankshaft from damage.
    Fig 8: Positioning Protective Sleeves On Connecting Rod
    G00325920Courtesy of KIA MOTORS AMERICA, INC.
  11. Check piston rings for correct end gap stagger.
  12. Place piston with "F" mark facing front of engine block, then slip piston and connecting rod assembly into a piston ring compressor.
    Fig 9: Compressing Piston Rings
    G00325921Courtesy of KIA MOTORS AMERICA, INC.
  13. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
  14. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine block.
  15. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft.
    NOTE: Follow this procedure for remaining piston and connecting rod assemblies.
  16. Install a connecting rod bearing in each connecting rod cap.
  17. Place a piece of Plastigauge (R) on crank pin journals.
  18. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.

    Tightening torque:

    22~24 lb-ft (29~34 N . m, 3.0~3.5 kg-m)

    NOTE:
    • When installing the connecting rods, match marks made on the connecting rod and cap to reference mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
    • When installing the piston assembly into cylinder block, position the piston between TDC and BDC, then install the cylinder head in order to prevent pistons and valves from contacts which may cause damage.
  19. Loosen and remove connecting rod caps.
  20. Check the connecting rod bearing clearance.

    Oil clearance:

    0.0010 ~ 0.0021 in (0.026 ~ 0.054 mm)

    Maximum: 0.004 in (0.10 mm)

    Fig 10: Identifying Connecting Rod Match Marks
    G00325922Courtesy of KIA MOTORS AMERICA, INC.
  21. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting rod bearings.
    Fig 11: Illustrating Connecting Rod Code Position
    G00325924Courtesy of KIA MOTORS AMERICA, INC.
    Fig 12: Connecting Rod Bearing Selection Table
    G00325923Courtesy of KIA MOTORS AMERICA, INC.
    Fig 13: Connecting Rod Bearing Housing Bore Size Chart
    G00325925Courtesy of KIA MOTORS AMERICA, INC.
    Fig 14: Connecting Rod Bearing Thickness Chart
    G00325926Courtesy of KIA MOTORS AMERICA, INC.
  22. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
  23. Install connecting rod cap and torque to specification.

    Tightening torque:

    22~24 lb-ft (29~34 N . m, 3.0~3.5 kg-m)

  24. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance.
    Fig 15: Measuring Connecting Rod Side Clearance
    G00325927Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Do not measure between connecting rod cap and crankshaft.

    Side clearance:

    0.0044~0.0103 in (0.110~0.262 mm)

    Maximum: 0.012 in (0.30 mm)

  25. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
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