Repair Procedures: Reassembly

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 (A) and the connecting rod front mark (B).
   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) to the other side after inserting the piston pin.
   Fig 3: Inserting Piston Pin Into Piston Pin Hole

   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.

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 maker mark facing upward.
3. Position the piston rings so that the ring ends are as shown. (The No. 1 ring should be on the opposite side of the No. 2 ring.) Example)
   Fig 4: Installing Piston Rings

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Confirm that the oil ring turns smoothly.

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 5: Installing Bearings In Connecting Rod And Connecting Rod Cap

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Be careful not to change the position of bearing caps.

• Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
• Install the piston and connecting rod assembly with the front marks facing the front of the engine.
  1. Install the ring compressor, check that the rings are securely in place, and then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
     Fig 6: Installing 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. Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.

     Tightening Torque  :

     [10.8 - 14.7 N.m (1.1 - 1.5 kgf.m, 8.0 - 10.9 lb.ft)] + [88 - 92°]

     Fig 7: Installing Rod Caps With Bearings

     Courtesy of KIA MOTORS AMERICA, INC.
     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. Reusing the removed bolts can cause the bolts to break or fail to maintain clamping force.

1. Clean the sealing face before assembling ladder frame and cylinder block.
2. Install the new O-ring (A) on the cylinder block.
   Fig 8: Installing O-Ring On Cylinder Block

   Courtesy of KIA MOTORS AMERICA, INC.
3. Apply liquid sealant TB 1217H on the oil pan. Assemble the part within 5 minutes of applying sealant.

   Bead Width  :

   2.5 mm (0.098 in.) - 3.5 mm (0.138 in.)

   Fig 9: Applying Liquid Sealant On Oil Pan

   Courtesy of KIA MOTORS AMERICA, INC.

Tightening Torque  :

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

Fig 10: Installing Ladder Frame

Courtesy of KIA MOTORS AMERICA, INC.