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Home >> Kia >> 2008 >> Spectra5 2.0 1, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> Engine Overhaul >> Engine Block >> Reassembly

Engine Block: Reassembly

NOTE:
  • Thoroughly clean all parts to 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.
  1. Assemble the piston and connecting rod.
    1. Use a hydraulic press for installation
    2. The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
      Fig 1: Positioning Piston-To-Connecting Rod
      G00719160Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the piston rings.
    1. Install the oil ring expander and 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
    3. Position the piston rings so that the ring ends are as shown. See Fig 2.
      Fig 2: Positioning Piston Rings
      G00719161Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the connecting rod bearings.
    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 3: Installing Connecting Rod Bearings
      G00719162Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the crankshaft main bearings.
    NOTE: Upper 1, 2, 4, 5 bearings have an oil groove of oil holes; Lower bearings do not.
    1. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A).
      Fig 4: Installing Upper Main Bearings
      G00719163Courtesy of KIA MOTORS AMERICA, INC.
    2. Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
  5. 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 5: Installing Thrust Bearing
    G00719164Courtesy of KIA MOTORS AMERICA, INC.
  6. Place the crankshaft on the cylinder block.
  7. Place the main bearing caps on the cylinder block.
  8. Install the main bearing cap bolts.
    NOTE:
    • The main bearing cap bolts are tightened in 2 progressive steps.
    • If any of the bearing cap bolts in broken or deformed, replace it.
    1. Apply a light coat of engine oil on the threads and under the bearing cap bolts.
    2. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in sequence. See Fig 6.

      Tightening torque: 27.5-31.4 N.m (2.8-3.2 kg-m, 20.3-23.1 lb-ft) + (60°-64°)

      Fig 6: Installing Main Bearing Cap Bolts
      G00719165Courtesy of KIA MOTORS AMERICA, INC.
    3. Check that the crankshaft turns smoothly.
  9. Check the crankshaft end play.
  10. Install the piston and connecting rod assemblies.
    NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
    1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
      2. NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
    2. 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.
    3. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
    4. Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the nuts.

      Tightening torque: 49.0-52.0 N.m (5.0-5.3 kg-m, 36.2-38.3 lb-ft)

    Fig 7: Installing Piston
    G00719166Courtesy of KIA MOTORS AMERICA, INC.
  11. Install a new gasket and rear oil seal case (A) with 5 bolts (B).

    Tightening torque: 9.8-11.8 N.m (1.0-1.2 kg-m, 7.2-8.7 lb-ft)

    Fig 8: Installing A New Gasket And Rear Oil Seal Case
    G00719167Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Check that the mating surfaces are clean and dry.
  12. Install the rear oil seal.
    1. Apply engine oil to a new oil seal lip.
    2. Using the Service Tool (09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
    Fig 9: Installing Rear Oil Seal
    G00719168Courtesy of KIA MOTORS AMERICA, INC.
  13. Install the front case.
  14. Install the oil screen.

    Install a new gasket (B) and oil screen (A) with 2 bolts (C).

    Tightening torque: 14.7-21.6 N.m (1.5-2.2 kg-m, 10.8-15.9 lb-ft)

    Fig 10: Installing Oil Screen
    G00719169Courtesy of KIA MOTORS AMERICA, INC.
  15. Install the oil pan.
    1. Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces
      NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket.
    2. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Liquid gasket: MS 721-40A or equivalent.
      NOTE:
      • To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes.
      • 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. After assembly, wait at least 30 minutes before filling the engine with oil.
    3. Install the oil pan (A) with the bolts. Uniformly tighten the bolts in several passes.

      Tightening torque: 9.8-11.8 N.m (1.0-1.2 kg-m, 7.2-8.7 lb-ft)

      Fig 11: Installing Oil Pan
      G00719170Courtesy of KIA MOTORS AMERICA, INC.
  16. Install the water pump.
  17. Install the oil pressure switch.
    1. Apply adhesive to 2 or 3 threads. Adhesive: MS 721-39 (B) or equivalent.
    2. Install the oil pressure switch (A).

      Tightening torque: 14.7-21.6 N.m (1.5-2. 2 kg-m, 10.8-15.9 lb-ft)

      Fig 12: Installing Oil Pressure Switch
      G00719171Courtesy of KIA MOTORS AMERICA, INC.
  18. Install the knock sensor (A).

    Tightening torque: 16.7-26.5 N.m (1.7-2.7 kg-m, 12.3-19.5 lb-ft)

    Fig 13: Installing Knock Sensor
    G00719172Courtesy of KIA MOTORS AMERICA, INC.
  19. Install the oil level gauge tube (A).
    1. Install a new O-ring on the oil level gauge tube.
    2. Apply engine oil on the O-ring.
    3. Install the oil level gauge tube (A) with the bolt.

      Tightening torque: 11.8-14.7 N.m (1.2-1.5 kg-m, 8.7-10.8 lb-ft)

      Fig 14: Installing Oil Level Gauge Tube
      G00719173Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the cylinder head. See INSTALLATION .
  21. Install the timing belt. See INSTALLATION .
  22. Remove the engine stand.
  23. A/T: install the drive plate (A) and washer (B).

    Tightening torque: 117.7-127.5 N.m (12.0-13.0 kg-m, 86.8-94.0 lb-ft)

    Fig 15: Installing Drive Plate
    G00719174Courtesy of KIA MOTORS AMERICA, INC.
  24. M/T: install the flywheel.

    Tightening torque: 117.7-127. N.m (12.0-13.0 kg-m, 86.8-94.0 lb-ft)

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