Replace connecting rod bearings on the 1.8L I4 engine, requiring complete engine disassembly from bottom end including oil pan, oil pump, and crankshaft removal.

Warnings

Tools required

Parts

• Connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Connecting rod bolts (TTY - replace mandatory) × 8 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pump O-ring × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• RTV silicone gasket maker (Kia approved) × 1 — Use OEM specification

Fluids

• Kia Genuine 5W-20 Engine Oil — 4.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 7.5 qt

Preparation

1. Disconnect negative battery cable and remove battery
2. Drain engine oil completely and remove oil filter
3. Drain cooling system completely into appropriate container
4. Remove engine splash shields and undercovers
5. Raise and securely support vehicle on jack stands at manufacturer lift points
6. Remove front wheels for access to subframe if needed
7. Install engine support fixture across engine bay to support engine weight
8. Label and photograph all electrical connections, vacuum lines, and coolant hoses before disconnection
9. Remove intake manifold and exhaust manifold for access
10. Remove accessory drive belts, alternator, A/C compressor (secure aside without disconnecting lines)
11. Clean exterior of engine thoroughly to prevent contamination during disassembly

Procedure

1. 1

   Remove timing chain and components
   Remove valve cover and timing chain cover. Mark timing chain orientation to camshaft and crankshaft sprockets. Remove timing chain tensioner, guides, and chain. Remove camshafts if necessary for clearance. Keep all components organized and labeled by position.
   Torque spec

   Cover Bolts15 Nm (11 lb-ft)
2. 2

   Remove oil pan and oil pickup
   Remove all oil pan bolts in reverse of tightening sequence. Carefully separate oil pan from block using plastic wedge tools - do not pry with metal tools. Remove oil pickup tube and screen assembly. Remove windage tray if equipped.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
3. 3

   Support engine and remove lower mounts
   Verify engine is securely supported by overhead fixture. Remove lower engine mount bolts and engine mounts. Lower engine slightly on support fixture to gain maximum clearance to oil pan rail and crankshaft.
   ⚠️Ensure engine support fixture is rated for engine weight and properly positioned before removing mounts.
   Torque spec

   Mounting Bolts45 Nm (33 lb-ft)
4. 4

   Mark and identify connecting rods
   Using permanent marker or stamps, clearly mark each connecting rod cap and rod body with cylinder number (1-4 from timing belt end) and orientation arrow pointing toward front of engine. Verify factory markings if present. Photograph rod cap orientation for reference.
   ⚠Rod caps are machined as matched sets with their rods. Mixing caps between rods will cause immediate bearing failure.
5. 5

   Remove connecting rod caps and inspect journals
   Rotate crankshaft to position cylinder 1 connecting rod at bottom dead center. Remove rod bolts and carefully remove rod cap, keeping bearing shell with cap. Slide protective hose over rod bolts to prevent crankshaft damage. Push piston/rod assembly up into bore and secure with clean towel. Repeat for all cylinders. Inspect each crankshaft rod journal for scoring, discoloration, or wear.
   ⚠Cover rod bolt threads with rubber hose immediately after cap removal to prevent scratching crankshaft journals during rotation.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
6. 6

   Measure crankshaft rod journals
   Using micrometer, measure each rod journal diameter in at least 4 locations (90° apart) and at both edges and center. Record all measurements. Check for taper (difference between front and rear measurements) and out-of-round (difference between perpendicular measurements). Maximum taper: 0.0012 inch, maximum out-of-round: 0.0008 inch. If beyond limits, crankshaft requires machining.
   ⚠Crankshaft journals worn beyond 0.001 inch or showing scoring require professional grinding and oversize bearings.
7. 7

   Clean all bearing surfaces
   Thoroughly clean all bearing surfaces on connecting rods, rod caps, and crankshaft journals using clean lint-free cloths and appropriate solvent. Remove all oil residue. Dry completely with compressed air. Inspect rod bores for damage or scoring. Verify oil passages in crankshaft and rods are clear by passing compressed air through them.
   ℹ️Any debris or contamination left on bearing surfaces will cause immediate failure. Cleanliness is critical.
8. 8

   Install and measure bearing clearances with Plastigage
   Install upper bearing shell in connecting rod (tang in notch, oil holes aligned). Place strip of Plastigage on crankshaft journal parallel to crankshaft centerline. Install lower bearing shell in cap. Install cap with NEW bolts in correct orientation. Torque bolts to 45 Nm (33 lb-ft) only - do NOT apply angle yet. Do not rotate crankshaft. Remove cap and measure Plastigage width using scale on package. Specified clearance: 0.0008-0.0016 inch. Repeat for all rods.
   ⚠Do not rotate crankshaft with Plastigage installed or measurement will be invalid. Remove all Plastigage residue before final assembly.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Install connecting rod bearings with assembly lube
   Remove all Plastigage residue completely. Install upper bearing shells in rods with tangs properly seated in notches. Coat bearing surfaces liberally with engine assembly lube. Lubricate crankshaft journals with assembly lube. Pull piston/rod assemblies down onto crankshaft journals one at a time, ensuring rod orientation is correct (markings toward front).
   ℹ️Apply generous assembly lube to all bearing surfaces. Initial engine start-up relies on this lubrication until oil pressure builds.
10. 10

    Install connecting rod caps with new bolts
    Install lower bearing shells in rod caps with tangs in notches. Apply assembly lube to bearing surfaces. Install rod caps in correct orientation matching cylinder numbers and orientation marks. Install NEW connecting rod bolts finger-tight. Verify cap is fully seated before tightening.
    ⚠️Only NEW TTY connecting rod bolts can be used. Old bolts have been permanently stretched and will fail.
11. 11

    Torque connecting rod bolts to specification
    Torque each connecting rod bolt to 45 Nm (33 lb-ft) using torque wrench. Then tighten each bolt an additional 90 degrees (1/4 turn) using angle gauge. Follow torque sequence: tighten one bolt to spec, apply angle, then repeat for second bolt on same cap. Verify both bolts are equally tight. After all rods are torqued, rotate crankshaft two complete revolutions by hand to verify smooth rotation with no binding.
    ⚠Torque-to-yield procedure requires both initial torque AND angle. Skipping angle step results in insufficient clamping force.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Reinstall oil pump and pickup
    Install new O-rings on oil pump and oil pickup. Install oil pump and torque mounting bolts. Install oil pickup tube and torque mounting bolts. Verify pickup tube is proper distance from oil pan floor (typically 5-7mm clearance).
    Torque spec

    Mounting Bolts45 Nm (33 lb-ft)

    Gasket Bolts19 Nm (14 lb-ft)
13. 13

    Install oil pan with new gasket
    Clean oil pan and block mating surfaces thoroughly. Install new oil pan gasket or apply RTV silicone in continuous bead as specified. Position oil pan carefully and install all bolts finger-tight. Torque oil pan bolts to 12 Nm (9 lb-ft) in proper tightening sequence starting from center and working outward in cross pattern. Allow RTV to cure per manufacturer specifications before filling oil.
    ℹ️Oil pan bolt tightening sequence is critical to prevent warping and leaks. Overtightening will distort pan flange.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
14. 14

    Reinstall timing components and engine mounts
    Reinstall timing chain, guides, and tensioner per alignment marks. Install timing chain cover with new gasket and torque bolts to specification. Install camshafts if removed. Reinstall engine mounts and torque all mount bolts. Remove engine support fixture. Reinstall all external components including manifolds, accessories, belts, and electrical connections.
    Torque spec

    Cover Bolts15 Nm (11 lb-ft)

    Mounting Bolts45 Nm (33 lb-ft)
15. 15

    Refill fluids and perform initial start
    Install oil drain plug with new crush washer and torque to specification. Install new oil filter. Fill engine with 4.5 quarts of Kia Genuine 5W-20 oil. Refill cooling system with 7.5 quarts of Hyundai/Kia Long Life Coolant. Reconnect battery. Before starting, remove fuel pump fuse and crank engine for 10 seconds to build oil pressure. Reinstall fuel pump fuse. Start engine and verify oil pressure immediately. Monitor for leaks and unusual noises. Allow engine to reach operating temperature and check coolant level.
    ⚠Oil pressure must register within 3-5 seconds of initial start. Shut down immediately if no oil pressure or unusual noises occur.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Reinstall all components in reverse order of removal
2. Use all new gaskets and seals throughout reassembly
3. Verify all electrical connectors are properly seated and locked
4. Torque all fasteners to specification - never reuse TTY bolts
5. Bleed cooling system after refilling to remove all air pockets
6. Check and top off all fluid levels after initial warm-up cycle

Verification

• Verify oil pressure reaches normal specification (29-72 psi at 3000 RPM) within seconds of starting
• Check for oil leaks around oil pan, timing cover, and all gasket surfaces with engine running
• Listen for abnormal noises including knocking, ticking, or rattling at idle and under light acceleration
• Monitor oil pressure gauge during 20-minute test drive under varying loads and RPM
• Perform cold restart after engine cools to verify bearing clearances are correct (no startup knock)
• Check for coolant leaks and verify proper operating temperature
• Verify no check engine lights or diagnostic codes are present
• After 500 miles, change oil and filter, inspect for metal particles in old oil indicating bearing wear

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