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Home › Kia › 2015 › Rio EX, 4D Hatchback › Repair and Diagnosis › Engine Mechanical › Mechanical › Cylinder Block › Repair Procedures › Reassembly

Repair Procedures: Reassembly

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.
  1. Assemble the piston and connecting rod.
    1. Use a hydraulic press for installation
    2. The piston front mark (A) and the connecting rod front mark (A) must face the timing chain side of the engine.
    Fig 1: Identifying Front Mark On Piston And Connecting Rod
    G08321115Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the piston rings.
    1. Install the oil ring coil spring 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 Installation Position
    G08321116Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the connecting rod bearings.
    1. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B).
    2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
    Fig 3: Identifying Connecting Rod Bearing And Cap
    G08321117Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the crankshaft main bearings.
    NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not.
    1. Align the bearing claw with the claw groove of the cylinder block, push in the five upper bearings(A).
      Fig 4: Identifying Crankshaft Upper Bearings
      G08321118Courtesy of KIA MOTORS AMERICA, INC.
    2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
  5. Install the thrust bearing.

    Install the thrust bearing (A) on the No. 3 journal position of the cylinder block with the oil grooves facing outward.

    Fig 5: Identifying Thrust Bearing
    G08321119Courtesy of KIA MOTORS AMERICA, INC.
  6. Place the crankshaft on the cylinder block.
  7. Place the main bearing caps on the cylinder block.
  8. Install the main bearing cap bolts.
    NOTE: The main bearing cap bolts are tightened in 2 progressive steps.

    If any of the bearing cap bolts in broken or deformed, replace it.

    1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
    2. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.

      Tightening torque: 

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

      Fig 6: Identifying Bearing Cap Bolts Tightening Sequence
      G08321120Courtesy of KIA MOTORS AMERICA, INC.
      CAUTION: Do not reuse the main bearing cap bolts.
    3. Check that the crankshaft turns smoothly.
  9. Check the crankshaft end play.
  10. Install the piston and connecting rod assemblies.
    NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
    1. Install the ring compressor, check that the rings are 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-crank journal alignment before pushing the piston into place.
    3. Install the rod caps with bearings, and tighten the bolts.

    Tightening torque: 

    17.7~21.8Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

    CAUTION: Do not reuse the connecting rod cap bolts.
  11. Apply the sealant on the ladder frame.
    Fig 7: Identifying Sealant Applying Areas On Ladder Frame
    G08321121Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Apply the sealant, THREE-BOND 1217H or LOCTITE 5900H on the ladder frame rail portion and install it with in five minutes.

      If when sealant is applied to cylinder block bottom position, sealant position to be same with position that is applied to ladder frame rail position.

    • Apply sealant along the inner line of the bolt holes.
  12. Install the ladder frame (A).

    Tightening torque: 

    18.6 ~ 24.2N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

    Fig 8: Identifying Ladder Frame
    G08321122Courtesy of KIA MOTORS AMERICA, INC.
  13. Install the rear oil seal.
    1. Apply engine oil to a new oil seal lip.
    2. Using the SST(09231-H1100, 09231-2B200) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
    Fig 9: Installing Rear Oil Seal Using SST And Hammer
    G08321123Courtesy of KIA MOTORS AMERICA, INC.
  14. Install the oil screen (A).

    Install a new gasket and oil screen with 2 bolts.

    Tightening torque: 

    19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

    Fig 10: Identifying Oil Screen And Mounting Bolts
    G08321124Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the oil pan.
    1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces.
      NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket.
    2. Apply liquid gasket with the width of Ø3mm, starting 1mm-away position from the inner rounding of the oil pan rail.

      Liquid gasket  : TB 1217H or LOCTITE 5900H

      Fig 11: Identifying Liquid Gasket Applying Areas On Oil Pan Rail
      G08321125Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
      • Do not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue.
      • After assembly, wait at least 30 minutes before filling the engine with oil.
    3. Install the oil pan (A) with the bolts.

      Uniformly tighten the bolts in several passes.

      Tightening torque: 

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

    Fig 12: Identifying Oil Pan And Mounting Bolts
    G08321126Courtesy of KIA MOTORS AMERICA, INC.
  16. Install the oil pressure switch.
    1. Apply adhesive to 2 or 3 threads.
    2. Install the oil pressure switch (A).

    Tightening torque: 

    7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

    Fig 13: Identifying Oil Pressure Switch
    G08321127Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the knock sensor (A) and the oil filter (B).

    Tightening torque: 

    16.7 ~ 26.5N.m (1.7 ~ 2.7kgf.m, 12.3 ~ 19.5lb-ft)

    Fig 14: Identifying Knock Sensor And Oil Filter
    G08321128Courtesy of KIA MOTORS AMERICA, INC.
  18. Install the oil level gauge tube.
    1. Install a new O-ring on the oil level gauge tube.
    2. Apply engine oil on the O-ring.
    3. Install the oil level gauge tube with the bolt.

      Tightening torque: 

      9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

  19. Install the water jacket insert (A).
    Fig 15: Identifying Water Jacket Insert
    G08321129Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Maximum height of installed water jacket insert must be below top surface of cylinder block.
  20. Install the cylinder head. (Refer to CYLINDER HEAD in this group)
  21. Install the timing chain. (Refer to TIMING CHAIN in this group)
  22. Remove the engine stand.
  23. A/T: install the drive plate.

    Tightening torque: 

    71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)

    Fig 16: Identifying Drive Plate And Mounting Bolts
    G08321130Courtesy of KIA MOTORS AMERICA, INC.
  24. M/T: install the fly wheel.

    Tightening torque: 

    71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)

  25. Install the engine. (Refer to ENGINE AND TRANSAXLE ASSEMBLY in this group)
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