Repair Procedures: Reassembly

NOTE:

Thoroughly clean all parts to be 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.

Install the main bearings.
NOTE: There are oil grooves or oil holes on upper bearings whereas there is none on lower bearings.
1. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings (A).
  
  Fig 1: Installing Upper Bearings
  Courtesy of KIA MOTORS AMERICA, INC.
2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
Install the thrust bearings.
Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

Fig 2: Installing Thrust Bearings
Courtesy of KIA MOTORS AMERICA, INC.
Place the crankshaft (A) on the cylinder block.

Fig 3: Placing Crankshaft On Cylinder Block
Courtesy of KIA MOTORS AMERICA, INC.
Place the main bearing caps on cylinder block.
Install the main bearing cap bolts.
1. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown.
  Tightening torque
  
  Main bearing cap bolt
  
  No. 1-8: 49.0 N.m (5.0 kgf.m, 36.2 lb.ft) + 90°
  
  No. 9-16: 19.6 N.m (2.0 kgf.m, 14.5 lb.ft) + 120°
  
  No. 17-24: 29.4 - 31.4 N.m (3.0 - 3.2 kgf.m, 21.7 - 23.1 lb.ft)
  
  Fig 4: Bearing Cap Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are torque-to-yield bolts designed to bepermanently 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.
  - If any of the bearing cap bolts are broken or deformed, replace it.
2. Check that the crankshaft turns smoothly.
Check crankshaft end play.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")
Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.

Tightening torque :

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

Fig 5: Baffle Plate Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the remaining parts in the reverse order of disassembly.
Information

After replacing the crankshaft with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft.
- Connecting rod bearing selection
  (Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")