Kia 230413C600 Piston & Pin Assembly

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Before the piston and connecting rod assemblies can be removed first the cylinder head, the oil pan and the upper oil pan needs to be detached. Run a fingernail at the top of the travel ring and if there is a ridge or any bump, then use the reamer for ridges or bumps to smoothen. Once you have gotten rid of the ridges, flip over the engine such that the crankshaft makes contact with the ground. Measure the connecting rod end play with feeler gases and do not allow it to exceed the service limit, if this is the case, then one may require new connecting rods. Being doing identification on the connecting rods and their caps then unbolt and remove the connecting rod cap and the bearing insert, while retaining the bearing insert, don't let it drop. Sliding the connecting rod/piston assembly up and out through the top of the engine: use a wooden or plastic hammer handle to gently ease the assembly out without marring the crankshaft. If resistance is felt, make sure that the ridge has been cleared to the brim. Do the same for the other cylinders and then put back the connecting rod caps and bearing inserts to their respective rods. The pistons and connecting rods will now look like this and will be suitable for inspection and reconditioning. When buying new piston rings, it is advisable to inspect the ring end gap, and also its piston ring side clearance. Place the piston/connecting rod assemblies on the bench and the new ring sets will have to be matched to each other during assembly. Place the top ring into the first cylinder with the flange square to the cylinder, and check the end gap with feeler gauges. If the gap is relatively narrow, patiently use the file to widen the ring ends. Conversely, published end gap is of little importance provided it is not too large estimate is that an end gap of more than about 0.030-inch can be a problem. Do this for each ring with the appropriate matching of materials for all the cylinders that is all. After that, ensure the end gaps are properly checked and adjusted, before fitting the rings onto the piston, in order of the oil control ring, then the middle and finally the top ring, while orientation ensures the identification marks on the rings face the right way. Before the installation it is recommended that cylinder walls should be free from any debris, top edge of the cylinder bore to be chamfered and the crank shaft positioned. Take off the cap of the specified connecting rod No. 1, decontaminate the bearings seat and fit new bearings with out applying any lubricant. Ensure the gaps of the piston ring are well oriented, apply a coat of oil on the piston and rings and use the piston ring compressor to introduce the piston into the cylinder properly. Swing the crankshaft to the bottom dead center and with the piston/connecting rod assembly in positioned, the connecting rod should lie across the crankshaft journal. Measure the oil clearance of the connecting rod bearing using Plastigage, the bearing faces should be free from any contaminants before the application of a thin layer of grease before the final tightening. Perform similar process with the remaining assemblies; always wash the assemblies and align them well. Proper final crankshaft installation should be followed by rotating the crankshaft with your hands and checking for tight binding and at the same time rechecking the connecting rod end play and adjusting as required.

Remove the cap from the number one connecting rod, clean the bearing surfaces, and install new bearing inserts without lubrication.