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Home >> Kia >> 2007 >> Rio5 Automatic >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> Engine Overhaul >> Engine Block >> Disassembly

Engine Block: Disassembly

  1. M/T: Remove the fly wheel.
  2. A/T: Remove the drive plate.
  3. Install the engine to engine stand for disassembly.
  4. Remove the timing belt. (Refer to REMOVAL  )
  5. Remove the cylinder head. (Refer to REMOVAL  )
  6. Remove the oil level gauge tube (A).
    Fig 1: Identifying Oil Level Gauge Tube
    G04861786Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the knock sensor (A).
    Fig 2: Identifying Knock Sensor
    G04861787Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the oil pressure switch (A).
    Fig 3: Identifying Oil Pressure Switch
    G04861788Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the water pump. (Refer to REMOVAL  )
  10. Remove the oil pan (A).
    Fig 4: Identifying Oil Pan
    G04861789Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the oil screen.

    Remove the 2bolts (C), oil screen (A) and gasket (B).

    Fig 5: Identifying Bolts, Oil Screen And Gasket
    G04861790Courtesy of KIA MOTORS AMERICA, INC.
  12. Check the connecting rod end play. (Refer to CONNECTING ROD AND CRANKSHAFT  )
  13. Remove the connecting rod caps and check oil clearance. (Refer to CONNECTING ROD AND CRANKSHAFT  )
  14. Remove the piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
      NOTE:
      • Keep the bearings, connecting rod and cap together.
      • Arrange the piston and connecting rod assemblies in the correct order.
  15. Remove the front case. (Refer to OIL PUMP  )
  16. Remove the rear oil seal case.

    Remove the 5bolts (B) and rear oil seal case (A).

    Fig 6: Identifying Bolts And Rear Oil Seal Case
    G04861791Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the crankshaft bearing cap and check oil clearance. (Refer to CONNECTING ROD BEARING SELECTION TABLE  )
  18. Check the crankshaft end play. (Refer to CRANKSHAFT MAIN BEARING SELECTION TABLE  )
  19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    NOTE: Arrange the main bearings and thrust bearings in the correct order.
    Fig 7: Identifying Crankshaft
    G04861792Courtesy of KIA MOTORS AMERICA, INC.
  20. 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.

  21. Remove the piston rings.
    1. Using a piston ring expender, remove the 2 compression rings.
    2. Remove the 2 side rails and oil ring by hand.
      NOTE: Arrange the piston rings in the correct order only.
  22. Remove the connecting rod from the piston.

    Using a press, remove the piston pin from piston. (Press-in load: 500~1,500kg (1,102~3,306lb))

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