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Home >> Kia >> 2003 >> Spectra Base, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 1.8L 4-Cylinder Engine >> Engine Disassembly, Inspection & Reassembly >> Reassembly

Engine Disassembly, Inspection & Reassembly: Reassembly

Fig 1: Illustrating Engine Block Components
G01080320Courtesy of KIA MOTORS AMERICA, INC.
  1. Clean all parts before assembly.
  2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
  3. Replace main bearings and rod bearings if they are peeling, burned or otherwise damaged.
    NOTE: Do not reuse old gaskets or seals.
  4. Install one piston pin clip into clip grooves on piston.
  5. Insert connecting rod into piston and slide piston pin through piston and through connecting rod until it makes contact with the piston pin clip already installed.
    NOTE: Verify that piston and rod are assembled in same direction as they were prior to disassembly.
    Fig 2: Installing Connecting Rod Onto Piston
    G01080321Courtesy of KIA MOTORS AMERICA, INC.
  6. Install second piston pin clip into clip grooves on opposite side of piston.
    Fig 3: Install Piston Pin Clip
    G01080322Courtesy of KIA MOTORS AMERICA, INC.
  7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.
  8. Install three piece oil ring onto piston.
    1. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
    2. Install expander onto piston so that expander ends face upward.
    3. Install lower oil ring onto piston. Ring may be installed with either face upward.
    4. Install upper oil ring onto piston. Ring may be installed with either face upward.
    Fig 4: Installing Lower Oil Ring Onto Piston
    G01080323Courtesy of KIA MOTORS AMERICA, INC.
  9. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
    Fig 5: Illustrating Oil Ring Position
    G01080324Courtesy of KIA MOTORS AMERICA, INC.
  10. Use a ring expander and install second ring.
  11. Use a ring expander and install top ring.
    NOTE: Top ring and second ring should be installed with "R" mark facing up.
    Fig 6: Illustrating Top & Second Ring Position
    G01080325Courtesy of KIA MOTORS AMERICA, INC.
  12. Align piston ring gaps as shown.
    Fig 7: Positioning Piston Ring Gaps
    G01080326Courtesy of KIA MOTORS AMERICA, INC.
  13. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes and main bearing journals thoroughly, and dry components with compressed air.
  14. Install grooved main bearings into saddles on engine block.
  15. Install thrust bearings with oil groove facing crankshaft.
    Fig 8: Installing Thrust Bearings
    G01080327Courtesy of KIA MOTORS AMERICA, INC.
  16. Set crankshaft on installed bearings.
  17. Install remaining main bearings into main bearing caps.
  18. Position Plastigage on crankshaft journals.
    Fig 9: Positioning Plastigage On Crankshaft Journals
    G01080328Courtesy of KIA MOTORS AMERICA, INC.
  19. Install main bearing caps along with lower main bearings according to cap number and mark.
  20. Tighten main bearing cap bolts according to the following procedure:
    1. Tighten bolts in order shown in figure. See Fig 10.

      Tightening torque: 28.9 lb-ft (39.2 N.m, 4kg-m) 

    2. Loosen bolts in reverse of order shown.
    3. Retighten bolts in order shown.

      Tightening torque: 14.5 lb-ft (19.6 N.m, 2kg-m) 

    4. Mark bolts for rotational reference.
    5. Rotate bolts 90° (1/4 Turn) in order shown.
    6. Rotate bolts another 60° (1/6 Turn) in order shown.
    CAUTION: Do not rotate crankshaft with Plastigage™ on crankshaft journals.
    Fig 10: Main Bearing Cap Bolt Tightening Sequence
    G01080329Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove main bearing caps and check bearing clearance.
    NOTE: The widest point of Plastigage™ is the smallest clearance, and the narrowest point of Plastigage is the largest clearance.
  22. If oil clearance exceeds specification, grind and polish crankshaft and use undersized main bearings.

    Oil Clearance: 0.00095-0.00165 in (0.024-0.042 mm) 

    Fig 11: Measuring Main Bearing Clearance
    G01080330Courtesy of KIA MOTORS AMERICA, INC.
  23. Lift crankshaft out of cylinder block and carefully remove Plastigage from main bearings and crankshaft journals.
  24. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
  25. Apply a light coat of oil on crankshaft main bearing journals and on main bearings on main bearing caps.
  26. Install main bearing caps along with lower main bearings according to cap number and <-- mark.
  27. Tighten main bearing cap bolts according to the following procedure:
    1. Tighten bolts in order shown in figure. See Fig 12.

      Tightening torque: 28.9 lb-ft (39.2 N.m, 4kg-m) 

    2. Loosen bolts in reverse of order shown.
    3. Retighten bolts in order shown.

      Tightening torque: 14.5 lb-ft (19.6 N.m, 2kg-m) 

    4. Mark bolts for rotational reference.
    5. Rotate bolts 90°(1/4 Turn) in order shown.
    6. Rotate bolts another 60°(1/6 Turn) in order shown.
    Fig 12: Main Bearing Cap Bolt Tightening Sequence
    G01080331Courtesy of KIA MOTORS AMERICA, INC.
  28. Rotate crankshaft to ensure it does not bind.
  29. Place a dial indicator against front of crankshaft and zero gauge.
  30. Using a prying tool, move crankshaft forward and zero dial indicator.
  31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator.

    End Play: 0.0032-0.0111 in (0.080-0.282 mm) 

    Fig 13: Measuring Crankshaft End Play
    G01080332Courtesy of KIA MOTORS AMERICA, INC.
  32. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft and thrust bearings.

    THRUST BEARING WIDTH 

    Fig 14: Measuring Thrust Bearing Width
    G01080334Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Thrust Bearing Width Specification Chart
    G01080333Courtesy of KIA MOTORS AMERICA, INC.
  33. Install a bearing into connecting rod.
  34. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
    Fig 16: Illustrating Connecting Rod Bolt Protective Sleeves
    G01080335Courtesy of KIA MOTORS AMERICA, INC.
  35. Check piston rings for correct end gap stagger.
  36. Place piston (cylinder number one) with"F"mark facing front of engine block, then slip piston and connecting rod assembly into a piston ring compressor.
  37. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottom dead center).
  38. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine block.
    Fig 17: Installing Piston And Connecting Rod Assembly
    G01080336Courtesy of KIA MOTORS AMERICA, INC.
  39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft.
    NOTE: Follow this procedure for remaining piston and connecting rod assemblies.
  40. Install a connecting rod bearing in each connecting rod cap.
  41. Place a piece of Plastigage™ on crank pin journals.
  42. Install connecting rod caps, aligning marks made previous to disassembly and torque to specification.

    Tightening torque: 34.7-36.9 lb-ft (47-50 N.m, 4.8-5.1 kg-m) 

    NOTE: When installing the connecting rods, match marks made on the connecting rod and cap to reference mark made on cylinder block to prevent oil starvation to the connecting rod bearings.
    Fig 18: Identifying Connecting Rod Mating Marks
    G01080337Courtesy of KIA MOTORS AMERICA, INC.
  43. Loosen and remove connecting rod caps.
  44. Check the connecting rod bearing clearance.

    Oil clearance: 0.0008-0.0019 in (0.020-0.05 mm) 

    Maximum : 0.004 in (0.10 mm) 

    Fig 19: Measuring Connecting Rod Bearing Clearance
    G01080338Courtesy of KIA MOTORS AMERICA, INC.
  45. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting rod bearings.
  46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
  47. Install connecting rod cap and torque to specification.

    Tightening torque: 34.7-36.9 lb-ft (47-50 N.m, 4.8-5.1 kg-m) 

  48. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod side clearance.
    NOTE: Do not measure between connecting rod cap and crankshaft.

    Side clearance: 0.0044-0.0103 in (0.110-0.262 mm) 

    Maximum: 0.012 in (0.30 mm) 

    Fig 20: Identifying Connecting Rod Side Clearance Measuring Location
    G01080340Courtesy of KIA MOTORS AMERICA, INC.
  49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.
    Fig 21: Identifying Engine Block External Components
    G01080339Courtesy of KIA MOTORS AMERICA, INC.
  50. Apply a light coat of clean engine oil to rear oil seal.
  51. Install rear oil seal into rear cover by hand.
  52. Press oil seal into rear cover.
    NOTE: Oil seal must be pressed in until it is nearly flush with surface of rear cover.

    Protrusion: 0-0.02 in (0-0.5 mm) 

    Fig 22: Installing Oil Seal Into Rear Cover
    G01080341Courtesy of KIA MOTORS AMERICA, INC.
  53. Apply a coat of silicone sealer to rear cover.

    Thickness: 0.08 in (2 mm) 

  54. Install the rear cover.

    Tightening torque: 5.8-8.0 lb-ft (7.8-10.8 N.m, 0.8-1.1 kg-m) 

  55. Remove any sealant that protrudes from rear cover onto oil pan mounting surface.
    Fig 23: Removing Any Protruding Sealant
    G01080342Courtesy of KIA MOTORS AMERICA, INC.
  56. Apply clean engine oil to new front oil seal and oil pump body.
  57. Install front oil seal by hand.
  58. Press oil seal into oil pump body.
    NOTE: Oil seal must be pressed in until it is nearly flush with front surface of oil pump body.

    Protrusion: 0.02-0.04 in (0.5-1.0 mm) 

    Fig 24: Installing Oil Seal Into Oil Pump Body
    G01080343Courtesy of KIA MOTORS AMERICA, INC.
  59. Install a new O-ring seal.
  60. Apply a bead of silicone sealant to oil pump body.

    Thickness: 0.04-0.08 in (1-2 mm) 

    CAUTION: Oil pump body must be installed within 5 minutes after silicone sealant is applied.
  61. Install oil pump with six bolts.

    Tightening torque: 14-19 lb-ft (19-26 N.m, 1.9-2.6 kg-m) 

  62. Remove any sealant that protrudes from oil pump onto oil pan mounting surface.
  63. Remove all foreign material from water pump mounting surface.
  64. Install water pump with a new gasket and torque to specification.

    Tightening torque: 14-19 lb-ft (19-26 N.m, 1.9-2.6 kg-m) 

    Fig 25: Installing Water Pump
    G01080345Courtesy of KIA MOTORS AMERICA, INC.
  65. Install oil pressure switch.

    Tightening torque: 8.7-13.7 lb-ft (11.7-17.6 N.m, 1.2-1.8 kg-m) 

  66. Apply a small amount of engine oil to rubber seal of oil filter.
  67. Install oil filter until rubber seal contacts base and then tighten filter 1 and 1/6 turn using an oil filter wrench.
    Fig 26: Installing Oil Pressure Switch And Oil Filter
    G01080346Courtesy of KIA MOTORS AMERICA, INC.
  68. Install oil strainer with a new gasket.

    Tightening torque: 5.8-8.7 lb-ft (7.8-11.8 N.m, 0.8-1.2 kg-m) 

    Fig 27: Installing Oil Strainer
    G01080347Courtesy of KIA MOTORS AMERICA, INC.
  69. Remove all foreign material from gasket surface.
  70. Apply a continuous bead of silicone sealant to oil pan contact surfaces.
    NOTE: Install oil pan within five minutes of applying silicone sealer.
    Fig 28: Applying Silicone Sealant To Oil Pan
    G01080348Courtesy of KIA MOTORS AMERICA, INC.
  71. Install oil pan and tighten oil pan bolts.

    Tightening torque: 5.8-8.0 lb-ft (7.8-10.8 N.m, 0.8-1.1 kg-m) 

    Fig 29: Identifying Oil Pan Bolt Positions
    G01080349Courtesy of KIA MOTORS AMERICA, INC.
  72. Clean thread sealant from flywheel bolts and bolt holes in crankshaft.
    NOTE: If thread sealant cannot be removed from bolt, replace flywheel bolt. If you are using new flywheel bolts, do not apply sealant: new bolts have sealant already applied to threads.
    Fig 30: Applying Sealant To Flywheel Bolts
    G01080350Courtesy of KIA MOTORS AMERICA, INC.
  73. Install separator plate onto cylinder block.

    Tightening torque: 13.7-22.4 lb-ft (18.6-30.4 N.m, 1.9-3.1 kg-m) 

  74. Install flywheel (M/T) or drive plate/backing plate/adapter (A/T) assembly onto crankshaft.
  75. Install bolts (apply sealant to reused bolts).
  76. Install locking tool.
  77. Tighten bolts in two or three steps to the specified torque.

    Tightening torque: 71-75.9 lb-ft (97-103 N.m, 9.8-10.5 kg-m) 

    Fig 31: Flywheel (M/T) Or Drive Plate/Backing Plate/Adapter (A/T) Bolt Tightening Sequence
    G01080351Courtesy of KIA MOTORS AMERICA, INC.
  78. Install clutch disc and clutch cover (M/T).
  79. Center the clutch disc with SST or equivalent and torque clutch cover bolts to specification (M/T).

    Tightening torque: 16-24 lb-ft (22-32 N.m, 2.2-3.3 kg-m) 

    Fig 32: Installing Clutch Disc And Clutch Cover
    G01080352Courtesy of KIA MOTORS AMERICA, INC.
  80. Remove locking tool.
  81. Remove all foreign material from contact surface of cylinder head and cylinder block.
  82. Place cylinder head gasket onto cylinder block and lower cylinder head onto cylinder block.
    Fig 33: Installing Cylinder Head Gasket
    G01080357Courtesy of KIA MOTORS AMERICA, INC.
  83. For additional cylinder head installation information, see CYLINDER HEAD ASSEMBLY .
  84. Install cylinder head bolts.
  85. Tighten cylinder head bolts according to following procedure:
    1. Tighten cylinder head bolts in order shown in figure. See Fig 34.

      Tightening torque: 36.1 lb-ft (49 N.m, 5 kg-m) 

    2. Loosen bolts in reverse of order shown.
    3. Retighten cylinder head bolts in order shown.

      Tightening torque: 28.9 lb-ft (39.2 N.m, 4 kg-m) 

    4. Mark cylinder head bolts for rotational reference.
    5. Rotate cylinder head bolts 90°(1/4 Turn) in order shown.
    6. Rotate cylinder head bolts another 90°(1/4 Turn) in order shown.
    Fig 34: Cylinder Head Bolt Tightening Sequence
    G01080358Courtesy of KIA MOTORS AMERICA, INC.
  86. Install HLA's. See HYDRAULIC LASH ADJUSTER (HLA) .
  87. For camshaft sprocket and timing belt information, see TIMING SYSTEM .
  88. Install new intake manifold gasket.
  89. Install intake manifold.

    Tightening torque: 13.7-18.8 lb-ft (18.6-25.5 N.m, 1.9-2.6 kg-m) 

  90. Install intake manifold bracket.

    Tightening torque: 27.5-38.3 lb-ft (37.2-51.9 N.m, 3.8-5.3 kg-m) 

    Fig 35: Installing Intake Manifold Bracket
    G01080359Courtesy of KIA MOTORS AMERICA, INC.
  91. Install generator and generator mounting bolts and adjusting bolt.
  92. Install generator belt and adjust it to specification.
    1. Generator drive belt deflection 
      1. New: 0.31-0.35 in (8-9 mm) 
      2. Used: 0.35-0.39 in (1-90 mm) 
  93. Tighten all bolts to specified torque.
    1. Tightening torque: 
      1. Mounting bolts: 27-38 lb-ft (37-52 N.m) 
      2. Adjusting bolt: 14-19 lb-ft (19-52 N.m) 
  94. Install front and rear engine hangers.
    Fig 36: Installing Front And Rear Engine Hangers And Grounds
    G01080360Courtesy of KIA MOTORS AMERICA, INC.
  95. Hang engine with baby crane from engine stand.
  96. Install exhaust manifold and coolant bypass pipe.
    1. Tightening torque: 
      1. A: 28.2-34 lb-ft (38.2-46.1 N.m, 3.9-4.7 kg-m) 
      2. B: 15.9-21 lb-ft (21.6-28.4 N.m, 2.2-2.9 kg-m) 
    Fig 37: Installing Exhaust Manifold Nuts
    G01080361Courtesy of KIA MOTORS AMERICA, INC.
  97. Install No. 3 engine mount and bracket.
    1. Tightening torque: 
      1. 54.1-75.9 lb-ft (73.5-102.9 N.m, 7.5-10.5 kg-m) 
    Fig 38: Installing No. 3 Engine Mount And Bracket
    G01080362Courtesy of KIA MOTORS AMERICA, INC.
  98. Install No. 2 engine mount.

    Tightening torque: 27.5-38.3 lb-ft (37.2-51.9 N.m, 3.8-5.3 kg-m) 

  99. Install transaxle and eight transaxle mounting bolts
    1. Tightening torque: 
      1. 4 upper bolts (1,2,3,4): 65.8-86.1 lb-ft (89-116 N.m, 9.1-11.9 kg-m) 
      2. 4 lower bolts (5,6,7,8): 27.5-38.3 lb-ft (37-52 N.m, 3.8-5.3 kg-m) 
    Fig 39: Installing Transaxle Mounting Bolts
    G01080363Courtesy of KIA MOTORS AMERICA, INC.
  100. Install starter.

    Tightening torque: 27-38 lb-ft (37-52 N.m, 3.7-5.8 kg-m) 

  101. Fill with specified type and amount of engine oil and check for leaks.
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