Kia Carens. Manual — part 28

37. Rotate engine block so that crankshaft is at Top Dead Center (TDC).

38. Rotate crankshaft so that No.1 and No. 4 cylinders are at Bottom Dead Center (BDC).

39. Use a numbering starmp and mark rod cap and connecting rod their cprresponding cylinder number.

Mark all rods on same side amd make a reference mark on block so that rods are installed in correct position
and direction. Failure to install rods properly with result in starvation, spun bearings, or damage internal engine
components.

40. Rotate crankshaft so that cylinders No. 2 and No.3 are at Bottom Dead Center (BDC) and repeat marking procedure.

41. Remove connecting rod nuts and gently loosen rod caps by tapping cap with a light plastic mallet.

42. Remove rod caps.

Cover connecting rod bolts to protect crankshaft journals.

43. Push connecting rod and piston as far up into cylinder as possible. Using wooden dowel, tap gently on piston to

release it from cylinder.

44. Repeat this procedure for each cylinder.

45. Mark tops of pistons with corresponding cylinder numbers they were removed from.

46. Using a piston ring expander, remove piston rings.

47. Hold piston upright and gently and move connecting rod.

48. Release connecting rod and observe its movment.

Do not swing connecting rod wildy. Constant hard contact with piston will cause a bell-mouth condition that will
require piston replacement.

49. If connecting rod does not move freely, check piston pin bore and connecting rod for straighness and deformation.

50. Remove piston pin clip from ends of piston pin bore.

51. Tilt piston pin clip to slide put to slide into your hand. Piston pins may need to be pressed out.

Do not allow pins to drop to the ground.

52. Remove connecting rod from piston. Keep individual piston pin and piston pin bore.

53. Mark main bearing caps (front to back) including direction.

Each main bearing cap is matched to that particular journal. Installing a cap wrong journal will caise an align
bore problem that will require an expensive machine precess to correct.

54. Loosen main bearing caps in two or three steps following order shown in figure.

55. Remove main bearing caps.

56. Grasp crankshaft and lift straight out.

57. Remove main bearings and thrust bearing from cylinder block saddles.

REASSEMBLY

Engine

1. Clean all parts before assembly.

2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.

3. Replace main bearing and rod bearing if they are peeling if they are peeling, burned or otherwise damaged.

Do not reuse old gasket or seals.

4. Install one piston pin clip groves on piston.

5. Install connecting rod into piston and slide piston pin through piston and through connecting rod until it makes contact

with the piston pin clip already installed.

Verify that piston and rod are assembled in same direction as they were prior to disassembly.

6. Install second piston pin clip into clip grooves on opposite side of piston.

7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely.

8. Install three piece oil ring onto piston.

A. Apply clean engine oil to the oil ring expander and upper and lower oil rings.
B. Install expander onto piston so that expander ends face upward.

C. Install lower oil ring onto piston. Ring may be installed with either face upward.
D. Install upper oil ring onto piston. Ring may be installed with either face upward.

9. Check that oil ring expander separates upper and lowe oil rings and that oil ring assembly spins freely on piston.

10. Use a ring expander and install second rod.

11. Use a ring expander and install top ring.

Top ring and second ring should be installed with "R" mark facing up.

12. Align piston rin gaps as shown.

13. Inspect journals and bearing for any foreign material. Clean cranksjaft. Oil holes and main bearing jounrals thoroghly

and dry components with compressed air.

14. Install grooved main bearing into saddles on engine block.

15. Install thrust bearing with oil groove facing crankshaft.

16. Set crankshaft on installed bearings.

17. Install remaining main bearing into main bearing caps.

18. Position Plastigage® on crankshft journals.

19. Install main bearing cap along with lower main bearing according to cap number and ←mark.

20. Tighten main bearing cap bolts according to the following procedure.

A. Tighten bolts in order shown.

Tightening torque : 28.9lb·ft (39.2N·m, 4kg-m)

B. Loosen bolts inreverse of order shown.

C. Retighten bolts in order shown.

Tightening torque : 14.5lb·ft (19.6N·m, 2kg-m)

D. Mark bolts for rotational reference.

E. Rotate bolts 90°(1/4turn) in order shown.

F. Rotate bolts another 60°(1/6 turn) in order shown.