Reassembly Kia Spectra I рестайлинг 2

Note. Thoroughly clean all parts to assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

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1. Assemble the piston and connecting rod. Use a hydraulic press for installation The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings. Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings. Align the bearing claw with the groove of the connecting rod or connecting rod cap. Install the bearings (A) in the connecting rod and connecting rod cap (B).
4. Install the crankshaft main bearings. NOTE: Upper 1, 2, 4, 5 bearings have an oil groove of oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A). Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the thrust bearings. Install the 2 thrust bearings (A) under the No. 3 journal position of the cylinder block with the oil grooves facing outward.
6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts. NOTE: The main bearing cap bolts are tightened in 2 progressive steps. If any of the bearing cap bolts in broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the bearing cap bolts. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown. Tightening torque : 27.5 ~ 31.4 N-m (2.8 ~ 3.2 kg-m, 20.3 ~ 23.1 lb-ft) + 60°~ 64° Check that the crankshaft turns smoothly.
9. Check the crankshaft end play.
10. Install the piston and connecting rod assemblies. NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts. NOTE: Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore. 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. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place. Apply engine oil to the bolt threads. Install the rod caps with bearings, and tighten the nuts. Tightening torque: 49.0 ~ 52.0 N-m (5.0 ~ 5.3 kg-m, 36.2 ~ 38.3 lb-ft)
11. Install a new gasket and rear oil seal case (A) with 5 bolts (B). Tightening torque: 9.8 ~ 11.8 N-m (1.0 ~ 1.2 kg-m, 7.2 ~ 8.7 lb-ft) NOTE: Check that the mating surfaces are clean and dry.
12. Install the rear oil seal. Apply engine oil to a new oil seal lip. Using the Service Tool (09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
13. Install the front case.
14. Install the oil screen. Install a new gasket (B) and oil screen (A) with 2 bolts (C). Tightening torque: 14.7 ~ 21.6 N-m (1.5 ~ 2.2 kg-m, 10.8 ~ 15.9 lb-ft)
15. Install the oil pan. 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. 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. Do 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. Install the oil pan (A) with the bolts. Uniformly tighten the bolts in several passes. Tightening torque: 9.8 ~ 11.8 N-m (1.0 ~ 1.2 kg-m, 7.2 ~ 8.7 lb-ft)
16. Install the water pump.
17. Install the oil pressure switch. Apply adhesive to 2 or 3 threads. Adhesive : MS 721-39 (B) or equivalent. Install the oil pressure switch (A). Tightening torque: 14.7 ~ 21.6 N-m (1.5 ~ 2. 2 kg-m, 10.8 ~ 15.9 lb-ft)
18. Install the knock sensor (A). Tightening torque: 16.7 ~ 26.5 N-m (1.7 ~ 2.7 kg-m, 12.3 ~ 19.5 lb-ft)
19. Install the oil level gauge tube (A). Install a new O-ring on the oil level gauge tube. Apply engine oil on the O-ring. Install the oil level gauge tube (A) with the bolt. Tightening torque: 11.8 ~ 14.7 N-m (1.2 ~ 1.5 kg-m, 8.7 ~ 10.8 lb-ft)
20. Install the cylinder head. See «INSTALLATION»(ref-272903-S35960233012007112900000) .
21. Install the timing belt. See «INSTALLATION»(ref-272903-S09443102792007112900000) .
22. Remove the engine stand.
23. A/T : install the drive plate (A) and washer (B). Tightening torque: 117.7 ~ 127.5 N-m (12.0 ~ 13.0 kg-m, 86.8 ~ 94.0 lb-ft)
24. M/T : install the fly wheel. Tightening torque: 117.7 ~ 127. N-m (12.0 ~ 13.0 kg-m, 86.8 ~ 94.0 lb-ft)

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1. Drain the engine coolant. WARNING: System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool.
2. Remove the drive belts.
3. Remove the timing belt. See «TIMING BELT»(ref-272903-S21027696902007112900000) .
4. Remove the timing belt idler.
5. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
6. Remove the bolts (B, C) and power steering pump bracket (A).
7. Remove the alternator. See «ALTERNATOR BELT INSPECTION & ADJUSTMENT»(ref-272904-S05652873142007112900000) .
8. Remove the water pump. Remove the 2 bolts (D) and alternator brace (A). Remove the 3 bolts (C) and remove the water pump (B) and gasket.