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

Repair Procedures: Reassembly

NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  1. Assemble the piston and connecting rod.
    1. Install the snap ring (A) on one side of the piston pin hole.
      G13704085Courtesy of KIA MOTORS AMERICA, INC.
    2. Align the piston front mark (A) and the connecting rod front mark (B).
      G13704086Courtesy of KIA MOTORS AMERICA, INC.
    3. Insert the piston pin (A) into the piston pin hole and the small end bore of connecting rod.
    4. Install the snap ring (B) in the other side after inserting the piston pin.
      G13704087Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • Apply a sufficient amount of engine oil to outer surface of the piston, inner surface of piston pin hole and small end bore of the connecting rod before inserting the piston pin.
      • Be careful not to damage and scratch the small end bore, piston pin hole and piston pin when inserting the piston pin.
      • Set the snap ring firmly so that the snap ring can contact with the whole groove of the piston pin hole.
      • Cutting face of snap ring must be located in the range of 45° to upper side.
        G13704088Courtesy of KIA MOTORS AMERICA, INC.
  2. Assemble the piston rings.
    1. Install the oil ring (two side rails) by hand.
    2. Using a piston ring expander, install the 2 compression rings with the maker mark facing upward.
    3. Position the piston rings so that the ring ends are as shown.
      G13704089Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: The side rail is an asymmetric barrel type and install it so that DMC mark faces upward (Cylinder head side).
      At this time, paint identification mark should be positioned at the right side of ring cutting section.
  3. Assemble the connecting rod bearings.
    1. Align the bearing claw with the groove of the connecting rod or connecting rod cap and install the bearings (A) in the connecting rod and connecting rod cap (B).
      G13704090Courtesy of KIA MOTORS AMERICA, INC.
    2. Apply a coat of engine oil after assembling the bearings.
  4. Insert the piston and connecting rod assemblies into the cylinder bores.
    NOTE:
    • Before installing the piston, apply a sufficient amount of engine oil to the ring grooves and cylinder bores.
    • Insert the piston front mark (A) and connecting rod front mark (B) facing the front of the timing chain.
      G13704091Courtesy of KIA MOTORS AMERICA, INC.
    1. Press the piston rings with a ring compressor and check that the rings are securely in place. Then insert the piston into the cylinder bore, and tap it in using the wooden handle of a hammer.
      G13704092Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
    2. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
    3. Install the connecting rod caps (A) with bearings, and tighten the bolts.

      Tightening torque: 

      17.7-21.8 N.m (1.8-2.2 kgf.m, 13.0-15.9 lb.ft) + 68-72°

      G13704093Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-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.
  5. Assemble the other parts in the reverse order of disassembly.
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