Kia Optima Manuals

Kia Forte: Piston and Connecting Rod Disassembly - Cylinder Block - Engine Mechanical System - Kia Forte TD 2014-2018 Service ManualKia Forte: Piston and Connecting Rod Disassembly

Second generation YD (2014-2018) / Kia Forte TD 2014-2018 Service Manual / Engine Mechanical System / Cylinder Block / Piston and Connecting Rod Disassembly

Engine removal is required for this procedure.
  
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature 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.
  
•
Mark all wiring and hoses to avoid misconnection.
•
Turn the crankshaft pulley so that the No.1 piston is at TDC (Top dead center).
1.
Remove the engine assembly from the vehicle.
(Refer to Engine And Transaxle Assembly - “Engine And Transaxle Assembly”)
2.
Remove the transaxle assembly from the engine assembly.
Manual Transaxle
(Refer to Manual Transaxle System - "Manual Transaxle")
Automatic Transaxle
(Refer to Automatic Transaxle System - "Automatic Transaxle")
3.
Manual Transaxle : Remove the flywheel.
(Refer to Cylinder Block - "Flywheel")
Automatic Transaxle : Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
4.
Remove the rear oil seal.
(Refer to Cylinder Block - “Rear Oil Seal”)
5.
Install the engine to engine stand for disassembly.
6.
Remove the timing chain.
(Refer to Timing System - “Timing Chain”)
7.
Remove the water pump assembly.
(Refer to Cooling System - “Water Pump”)
8.
Remove the water inlet fitting and the thermostat assembly.
(Refer to Cooling System - “Thermostat“)
9.
Remove the intake manifold.
(Refer to Intake And Exhaust System - "Intake Manifold")
10.
Remove the A/C compressor.
(Refer to Heating, Ventilation Air conditioning -"Compressor")
11.
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
12.
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
13.
Remove the oil filter.
(Refer to Lubrication System - “Engine Oil”)
14.
Remove the oil screen.
(Refer to Lubrication System - “Oil Pan”)
15.
Remove the knock sensor (A).
16.
Remove the oil pressure switch (OPS) (B).
17.
Remove the crankshaft position sensor (CKPS) (C).
18.
Check the connecting rod side clearance.
19.
Check the connecting rod bearing cap oil clearance.
20.
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).

  
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 with upper bearing through the top of the cylinder block.
  
•
Keep the connecting rod ands cap 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.
21.
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.
22.
Remove piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings.
(2)
Remove 2 side rails and the oil ring by hand.
  
Arrange the piston rings in the correct order.
23.
Disassemble the connecting rod from the piston.
(1)
Remove the snap ring (A) from the piston.
(2)
Remove the piston pin (B) from piston.
(3)
Disassemble the piston (C) and connecting rod (D).

Piston and Connecting Rod Components
1. Piston ring 2. Snap ring 3. Piston pin 4. Piston 5. Connecting rod 6. Connecting rod upper bearing 7. Connecting rod lower bearing 8. Connecting rod bearing cap ...

Piston and Connecting Rod Inspection
Connecting Rod 1. Check the connecting rod side clearance. Using a feeler gauge, measure the end play while moving the connecting rod back and forth. ...

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