Engine Block Reassembly

1. Install the expander.
   Fig 1: Positioning Oil Ring Onto Piston (1 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 2: Positioning Oil Ring Onto Piston (2 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.
2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove (as illustrated).
   CAUTION: Do not use a piston ring expander when installing the side rail.
3. Install the lower side rail by the same procedure described in Step 2.
   Fig 3: Installing Oil Ring Lower Side Rail

   Courtesy of KIA MOTORS AMERICA, INC.
4. Apply engine oil around the piston and piston grooves.
5. Using a piston ring expander, install the No. 2 piston ring.
6. Install the No. 1 piston ring.
   Fig 4: Installing Top Two Piston Rings

   Courtesy of KIA MOTORS AMERICA, INC.
7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions.
8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
   Fig 5: Positioning Piston Rings

   Courtesy of KIA MOTORS AMERICA, INC.
9. Install the upper main bearings in the cylinder block.
10. Install the lower main bearings in the main bearing caps.
    CAUTION: Install the bearing so it matches the oil hole in the block.
    Fig 6: Installing The Lower Main Bearings

    Courtesy of KIA MOTORS AMERICA, INC.
11. Install the thrust washers in the No. 3 main bearing Journal (Block side) with the oil grooves facing outward.
    Fig 7: Installing Thrust Bearing

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12. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap at disassembly match.
14. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
15. When assembling, bolts should be fastened using the plastic angle technique as follows.
    1. Apply oil to the threads and matching areas.
    2. Tighten the connecting rod bolt.

    Tightening torque 

    Connecting rod bolt:

    35 N.m+92° (350 kg°Cm+92°, 26 lb.ft+92°).

    CAUTION: After removing the connecting rod bolt, do not use it again.
    When using a new bolt, do not tighten the bolt more than 3 times.
16. Check the connecting rod side clearance.

Connecting rod side clearance 

Standard: 0.10-0.25 mm (0.0039-0.0098 in.).

Limit: 0.4 mm (0.0157 in.).

Fig 8: Measuring Connecting Rod Side Clearance

Courtesy of KIA MOTORS AMERICA, INC.