Repair Procedures: Reassembly

NOTE:

Thoroughly clean all parts to be 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.

Assemble the piston and the connecting rod.
1. Install the piston pin with two snap rings and check the snap ring assembly thoroughly.
2. The piston front mark (A) and the connecting rod front mark (B) must face the timing belt side of the engine.
  
  Fig 1: Locating Piston Front Mark And Connecting Rod Front Mark
  Courtesy of KIA MOTORS AMERICA, INC.
Install the piston rings.
1. Install the coil spring and oil ring 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.
  
  Fig 2: Positioning Piston Ring Ends
  Courtesy of KIA MOTORS AMERICA, INC.
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 Bearings In Connecting Rod And Connecting Rod Cap
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: When reassembling the connecting rods and caps, check the front marks and the number of cylinder.
Attach the piston and connecting rod assemblies on the cylinder block.
NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
1. Install the ring compressor, and check that the bearing is securely in place. Then, position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
2. Stop when the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
3. Install the rod caps with bearings, and torque the bolts.
  Tightening torque :
  
  [27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)] + [68 - 72°]
  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, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
  - Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
Fig 4: Installing Ring Compressor
Courtesy of KIA MOTORS AMERICA, INC.
Install the baffle plate.
Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.

Tightening torque :

9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

Fig 5: Baffle Plate Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the remaining parts in the reverse order of disassembly.