Cylinder Block - 2.4L: Overview Kia Optima II рестайлинг

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1. M/T : remove flywheel.
2. A/T : remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing chain. (Refer to «TIMING SYSTEM - 2.4L»(ref-357424) in this group)
5. Remove cylinder head. (Refer to «CYLINDER BLOCK»(ref-357426-S33075379052010032300000) in this group)
6. Remove A/C compressor(A) from engine.
7. Remove alternator(A) from engine.
8. Remove power steering pump and bracket.
9. Remove tensioner assembly integrated bracket(A).
10. Remove oil level gauge assembly(A).
11. Remove knock sensor(A).
12. Remove oil pressure sensor(A).
13. Remove CKP sensor(A).
14. Remove water pump.
15. Remove balance shaft module.
16. Remove ladder frame(A).
17. Check the connecting rod end play.
18. Remove the connecting rod caps and check oil clearance.
19. Remove piston and connecting rod assemblies. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
20. Remove crankshaft bearing cap and check oil clearance.
21. Check the crankshaft end play.
22. Lift the crankshaft(A) out of the engine, being careful not to damage journals. NOTE: Arrange the main bearings and thrust bearings in the correct order.
23. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
24. Remove piston rings. Using a piston ring expender, remove the 2 compression rings. Remove 2 side rails and the spacer by hand. NOTE: Arrange the piston rings in the correct order only.
25. Disconnect connecting rod from piston.

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1. Check the connecting rod end play. Using a feeler gauge, measure the end play while moving the connecting rod back and forth. Standard end play: 0.1~ 0.25mm (0.004 ~ 0.010in.) Maximum end play: 0.35mm (0.0138in.) If out-of-tolerance, install a new connecting rod. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove 2 connecting rod cap bolts. Remove the connecting rod cap and bearing half. Clean the crank pin and bearing. Place plastigage across the crank pin. Reinstall the bearing half and cap, and torque the bolts. Tightening torque 17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92° NOTE: Do not turn the crankshaft. Remove 2 bolts, connecting rod cap and bearing half. Measure the plastigage at its widest point. Standard oil clearance 0.028 ~ 0.046mm(0.0011 ~ 0.0018in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

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Discrimination Of Connecting Rod

CONNECTING ROD INSIDE DIAMETER CHART

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Discrimination Of Crankshaft

CRANKSHAFT OUTSIDE DIAMETER CHART

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Discrimination Of Connecting Rod Bearing

BEARING THICKNESS CHART

1. (11) Selection CONNECTING ROD IDENTIFICATION MARK CHART Crankshaft Identification Mark Connecting Rod Identification Mark Assembling Classification Of Bearing I (1) a (A) D (YELLOW) b (B) C (GREEN) c (C) B (NONE) II (2) a (A) C (GREEN) b (B) B (NONE) c (C) A (BLACK) III (3) a (A) B (NONE) b (B) A (BLACK) c (C) AA (BLUE)

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1. 3. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves. Clean each main journal and bearing half with a clean shop tower. Place one strip of plastigage across each main journal. Reinstall the bearings and caps, then torque the bolts. Tightening torque 14.7Nm (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125° NOTE: Do not turn the crankshaft. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance 0.020 ~ 0.038mm (0.0008 ~ 0.0015in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.