Kia Rio: Reassembly
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Thoroughly clean all parts to assembled.
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Before installing the parts, apply fresh engine oil to
all sliding and rotating surfaces.
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Replace all gaskets, O-rings and oil seals with new parts.
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1. |
Assemble the piston and connecting rod.
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(1) |
Use a hydraulic press for installation
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(2) |
The piston front mark (A) and the connecting rod front
mark (A) must face the timing chain side of the engine.
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2. |
Install the piston rings.
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(1) |
Install the oil ring coil spring and 2 side rails by hand.
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(2) |
Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
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(3) |
Position the piston rings so that the ring ends are as
shown.
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3. |
Install the connecting rod bearings.
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(1) |
Align the bearing (A) claw with the groove of the connecting
rod or connecting rod cap (B).
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(2) |
Install the bearings (A) in the connecting rod and connecting
rod cap (B).
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4. |
Install the crankshaft main bearings.
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Upper bearings have an oil groove of oil holes ; Lower
bearings do not.
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(1) |
Align the bearing claw with the claw groove of the cylinder
block, push in the five upper bearings(A).
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(2) |
Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
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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.
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6. |
Place the crankshaft on the cylinder block.
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7. |
Place the main bearing caps on the cylinder block.
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8. |
Install the main bearing cap bolts.
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Always use new crankshaft main bearing cap bolts.
Crankshaft main bearing cap bolts are toque-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.
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The main bearing cap bolts are tightened in 2
progressive steps.
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If any of the bearing cap bolts in broken or deformed,
replace it.
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(1) |
Apply a light coat of engine oil on the threads and under
the bearing cap bolts.
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(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°
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Always use new crankshaft main bearing cap bolts.
Crankshaft main bearing cap bolts are toque-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.
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(3) |
Check that the crankshaft turns smoothly.
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9. |
Check the crankshaft end play.
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10. |
Install the piston and connecting rod assemblies.
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Before installing the piston, apply a coat of engine oil
to the ring grooves and cylinder bores.
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(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.
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(2) |
Stop after the ring compressor pops free, and check the
connecting rod-to-crank journal alignment before pushing the
piston into place.
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(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°
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Always use new connecting rod cap bolts. Connecting
rod cap bolts are toque-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.
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11. |
Apply the sealant on the ladder frame.
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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 positon that
is applied to ladder frame rail position.
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Apply sealant along the inner line of the bolt
holes.
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12. |
Install the ladder frame (A).
Tightening torque :
18.6 ~ 24.2N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
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13. |
Install the rear oil seal.
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(1) |
Apply engine oil to a new oil seal lip.
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(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.
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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)
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15. |
Install the oil pan.
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(1) |
Using a razor blade and gasket scraper, remove all the
old packing material from the gasket surfaces.
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Check that the mating surfaces are clean and dry
before applying liquid gasket.
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(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
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To prevent leakage of oil, apply liquid
gasket to the inner threads of the bolt holes.
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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.
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After assembly, wait at least 30 minutes
before filling the engine with oil.
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(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)
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16. |
Install the oil pressure switch.
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(1) |
Apply adhesive to 2 or 3 threads.
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(2) |
Install the oil pressure switch (A).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
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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)
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18. |
Install the oil level gauge tube.
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(1) |
Install a new O-ring on the oil level gauge tube.
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(2) |
Apply engine oil on the O-ring.
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(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)
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19. |
Install the water jacket insert (A).
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Maximum height of installed water jacket insert must be
below top surface of cylinder block.
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20. |
Install the cylinder head. (Refer to Cylinder head in this group)
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21. |
Install the timing chain. (Refer to Timing chain in this group)
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22. |
Remove the engine stand.
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23. |
A/T :install the drive plate.
Tightening torque :
71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)
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24. |
M/T :install the fly wheel.
Tightening torque :
71.6 ~ 75.5N.m (7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft)
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25. |
Install the engine. (Refer to Engine and transaxle assembly in
this group)
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Connecting Rod And Crankshaft
1.
Check the connecting rod end play.
Using feeler gauge, measure the end play while moving the connecting
rod back and f ...
Inspection
Cooling System