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

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

  
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1.
Assemble the piston and the connecting rod.
(1)
Install the snap ring (A) in one side of the piston pin hole.
(2)
Align the piston front mark and the connecting rod front mark.
(3)
Insert the piston pin (B) into the piston pin hole and the small end bore of connecting rod.
(4)
Install the snap ring (C) in the other side after inserting the piston pin.

  
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.
2.
Install the piston rings.
(1)
Install the oil ring spacer and 2 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. (The No.1 ring should be on the opposite side of the No.2 ring.)
Example)

  
Check to ensure that the oil ring can be turned smoothly.
3.
Install the connecting rod bearings.
(1)
Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2)
Install the bearings (A) in the connecting rod and connecting rod cap (B).

  
Be careful not to change the position of bearing caps.
4.
Install the piston and connecting rod assemblies.
A.
Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores.
B.
Install the piston and connecting rod assembly with the front marks facing the front of the engine.
(1)
Install the ring compressor, check that the rings are securely in place, and then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.

(2)
Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
(3)
Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the bolts.

Tightening torque
1st step :
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft)
2nd step : 88 ~ 92°

Using the SST (09221-4A000), tighten the connecting rod cap bolts.

  
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.
  
Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
5.
Check the connecting rod end play.
6.
Assemble the other parts in the reverse order of disassembly.
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. ...

Crankshaft Components
1. Crankshaft upper bearing 2. Crankshaft thrust bearing 3. Crankshaft 4. Crankshaft lower bearing 5. Crankshaft position sensor (CKPS) wheel 6. Lower crankcase 7. Gas ...

See also:

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Cylinder Head Reassembly
   • Thoroughly clean all parts to be assembled. • ...

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