Engine Block: Reassembly

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: Identifying Piston Front Mark And Connecting Rod Front Mark

   Courtesy of KIA MOTORS AMERICA, INC.

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.
   Fig 2: Identifying Piston Rings Position

   Courtesy of KIA MOTORS AMERICA, INC.

1. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B).
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
   Fig 3: Identifying Bearings And Connecting Rod Cap

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1. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A).
   Fig 4: Identifying Upper Bearings

   Courtesy 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.

Install the center bearing (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

Fig 5: Identifying Center Bearing

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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 the sequence shown.

   Tightening torque : 

   53.9~58.8N.m (5.5~6.0kgf.m, 39.8~43.4lb-ft)

   Fig 6: Identifying Tightening Sequence Of Bearing Cap Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
3. Check that the crankshaft turns smoothly.

1. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts
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 : 

   31.4~34.3N.m (3.2~3.5kgf.m, 23.1~25.3lb-ft)

   NOTE: Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
   Fig 7: Installing Piston And Connecting Rod Assemblies

   Courtesy of KIA MOTORS AMERICA, INC.

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

3. Install the rear oil seal case (A) with 5 bolts (B).

   Tightening torque : 

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

   Fig 8: Identifying Bolts And Rear Oil Seal Case

   Courtesy of KIA MOTORS AMERICA, INC.

1. Apply engine oil to a new oil seal lip.
2. Using the SST (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

   Courtesy of KIA MOTORS AMERICA, INC.

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

Tightening torque : 

14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)

Fig 10: Identifying Bolts, Oil Screen And Gasket

Courtesy of KIA MOTORS AMERICA, INC.

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.
   • D 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 : 

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

   Fig 11: Identifying Oil Pan

   Courtesy of KIA MOTORS AMERICA, INC.

1. Apply adhesive to 2 or 3 threads.

   Adhesive: MS 721-39 (B) or equivalent.

2. Install the oil pressure switch (A).

   Tightening torque : 

   14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)

   Fig 12: Identifying Oil Pressure Switch

   Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque : 

16.7~26.5N.m (1.7~2.7kgf.m, 12.3~19.5lb-ft)

Fig 13: Identifying Knock Sensor

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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 : 

   11.8~14.7N.m (1.2~1.5kgf.m, 8.7~10.8lb-ft)

   Fig 14: Identifying Oil Level Gauge Tube

   Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque : 

117.7~127.5N.m (12.0~13.0kgf.m, 86.8~94.0lb-ft)

Fig 15: Identifying Drive Plate

Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque : 

117.7~127.5N.m (12.0~13.0kgf.m, 86.8~94.0lb-ft)