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Home >> Kia >> 2011 >> Rio Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block >> Repair Procedures >> Disassembly

Repair Procedures: 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 TIMING SYSTEM )
  5. Remove the cylinder head. (Refer to CYLINDER HEAD ASSEMBLY )
  6. Remove the oil level gauge tube (A).
    Fig 1: Identifying Oil Level Gauge Tube
    G06828548Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the knock sensor (A).
    Fig 2: Identifying Knock Sensor
    G06828549Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the oil pressure switch (A).
    Fig 3: Identifying Oil Pressure Switch
    G06828550Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the water pump. (Refer to WATER PUMP )
  10. Remove the oil pan (A).
    Fig 4: Identifying Oil Pan
    G06828551Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the oil screen.

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

    Fig 5: Identifying Oil Screen, Gasket And Bolts
    G06828552Courtesy 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 ENGINE AND TRANSAXLE ASSEMBLY )
  16. Remove the rear oil seal case.

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

    Fig 6: Identifying Rear Oil Seal Case And Bolts
    G06828553Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the crankshaft bearing cap and check oil clearance. (Refer to COMPONENT )
  18. Check the crankshaft end play. (Refer to COMPONENT )
  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
    G06828554Courtesy 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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