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Home >> Kia >> 2021 >> Rio LX >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block Assembly >> Piston And Connecting Rod >> Repair Procedures >> Disassembly

Repair Procedures: Disassembly

NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
  • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Information 

  1. Remove the engine and transaxle assembly from the vehicle.

    (Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")

  2. Remove the intelligent variable transmission (IVT).

    (Refer to Intelligent Variable Transmission (IVT) System (Continuously Variable Transmission) - "INTELLIGENT VARIABLE TRANSMISSION (IVT) ")

  3. Intelligent variable transmission (IVT): Remove the drive plate.

    (Refer to Cylinder Block - "DRIVE PLATE ")

  4. Remove the rear oil seal.

    (Refer to Cylinder Block Assembly - "REAR OIL SEAL ")

  5. Install the engine assembly to engine stand for disassembly.
  6. Remove the oil pan.

    (Refer to Lubrication System - "OIL PAN ")

  7. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  8. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  9. Remove the exhaust manifold.

    (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

  10. Remove the electric EGR control valve.

    (Refer to "REPAIR PROCEDURES ")

  11. Remove the EGR cooler.

    (Refer to Intake And Exhaust System - "EGR COOLER ")

  12. Remove the oil filter body.

    (Refer to Lubrication System - "OIL FILTER BODY ")

  13. Remove the oil pump.

    (Refer to Lubrication System - "OIL PUMP ")

  14. Remove the cylinder head assembly.

    (Refer to Cylinder Head Assembly - "CYLINDER HEAD ")

  15. Check the connecting rod side clearance.
  16. Check the connecting rod bearing cap oil clearance.
  17. Remove the piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod bearing caps (A).
      G13704070Courtesy of KIA MOTORS AMERICA, INC.

      Information 

      Mark the connecting rod, and caps to be able to reassemble in the original position and direction.

    3. Push the piston and connecting rod assembly (A) with upper bearing through the top of the cylinder block.
      G13704071Courtesy of KIA MOTORS AMERICA, INC.

      Information 

      • Keep the connecting rods and caps with their bearings assembled together.
      • Arrange the piston and connecting rod assemblies in the correct order.
      • Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
  18. Check fit between piston and piston pin.

    Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

  19. Disassemble the piston rings.
    1. Using a piston ring expender, remove the two compression rings (A).
    2. Remove the oil ring (B) by hand.
      NOTE: Do not apply excessive force to remove the oil ring from piston. It may cause to break the oil ring.

      Information 

      Arrange the piston rings in the correct order only.

  20. Disassemble the piston and connecting rod.
    1. Remove the snap ring (C).
    2. Remove the piston pin (D) from the piston.
    3. Remove the piston (E) and connecting rod (F).
      G13704072Courtesy of KIA MOTORS AMERICA, INC.
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