Cylinder Block - 2.7L: Overview Kia Optima II рестайлинг

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1. Remove the drive plate (A).
2. Remove the rear plate (A).
3. Remove timing belt.
4. Remove intake manifold.
5. Remove exhaust manifold.
6. Remove generator from engine.(Refer to «CHARGING SYSTEM»(ref-357433) ).
7. Remove power steering pump from engine.(Refer to «HYDRAULIC POWER STEERING SYSTEM»(/kia/optima/ii-2008-2010/remont/manual-power-steering/#hydraulic-power-steering-system) ).
8. Remove cylinder head.
9. Remove A/C compressor from engine.(Refer to «AIR CONDITIONING SYSTEM»(ref-357504) ).
10. Remove water pump assembly.

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1. Remove the power steering pump bracket (A) and the knock sensor (B).
2. Remove the air conditioning compressor bracket (A).
3. Remove the lower oil pan (A). CAUTION: When removing the oil pan, use the SST (09215-3C000) not to damage the contacting surface of the oil pan.
4. Remove the oil screen (A).
5. Remove the upper oil pan (A). CAUTION: When removing the oil pan, use the SST (09215-3C000) not to damage the contacting surface of the oil pan.
6. Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies. NOTE: Keep the bearings the connecting rods and the caps together. Arrange the piston and connecting rod assemblies in the correct order.
9. Remove the oil pump case.
10. Remove the oil seal case (A).
11. Check the crankshaft end play.
12. Remove the crankshaft bearing cap and check oil clearance. NOTE: Arrange the bearings and the bearing caps in order.
13. Lift the crankshaft (A) out of the block, being careful not to damage journals.
14. Remove and arrange the main bearings and thrust bearings in the correct order.
15. Remove the CKP sensor (A).
16. Check the free play between a piston and a piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston pin as a set.
17. Remove the piston rings. Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and the oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
18. Disconnect the connecting rod from the piston. Using a press, remove the piston pin from the piston. (Press-in load: 2451.7 ~ 12258.3N (250 ~ 1250kg, 551.2 ~ 2755.81lb)

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1. Check the connecting rod side clearance. Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth. Specification Standard: 0.1~ 0.25mm (0.0039 ~ 0.0098in.) Limit: 0.4mm (0.0157in.) If out-of-tolerance, install a new connecting rod. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Remove the connecting rod cap and the lower bearing. Clean the crankshaft pin journal and the bearing. Place a plastigage across the crankshaft pin. Reinstall the lower bearing and the connecting rod cap and torque the bolts. Tightening torque 17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 90~94° NOTE: Do not turn the crankshaft. Remove the connecting rod cap again. Measure the plastigage at its widest point. Standard oil clearance 0.018 ~ 0.036mm (0.0007 ~ 0.0014in.) 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. Connecting Rod Mark Location Discrimination Of Connecting Rod CONNECTING ROD MARK SPECIFICATION Class Mark Inside Diameter 0 a 51.000 ~ 51.006mm (2.0079 ~ 2.0081in.) 1 b 51.006 ~ 51.012mm (2.0081 ~ 2.0083in.) 2 c 51.012 ~ 51.018mm (2.0083 ~ 2.0086in.) Crankshaft Pin Mark Location Discrimination Of Crankshaft Discrimination Of Crankshaft CRANKSHAFT PIN MARK CHART Class Mark Outside Diameter Of Pin I 1 or A 47.994 ~ 48.000mm (1.8895 ~ 1.8898in.) II 2 or B 47.988 ~ 47.994mm (1.8893 ~ 1.8895in.) III 3 or C 47.982 ~ 47.988mm (1.8891 ~ 1.8893in.) Place Of Identification Mark (Connecting Rod Bearing) Discrimination Of Connecting Rod Bearing BEARING THICKNESS CHART Class Mark Thickness Of Bearing A Blue 1.5000 ~ 1.503mm (0.0591 ~ 0.0592in.) B Black 1.497 ~ 1.500mm (0.0589 ~ 0.0591in.) C - 1.494 ~ 1.497mm (0.0588 ~ 0.0589in.) D Green 1.491 ~ 1.494mm (0.0587 ~ 0.0588in.) E Yellow 1.488 ~ 1.491mm (0.0586 ~ 0.0587in) Select the proper connecting rod bearing from the table below. CONNECTING ROD IDENTIFICATION MARK CHART Connecting Rod Identification Mark 0 (A) 1 (B) 2 (C) Crankshaft Identification Mark I (A) E (Yellow) D (Green) C (-) II (B) D (Green) C (-) B (Black) III (C) C (-) B (Black) A (Blue)
3. Check the connecting rod. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction. If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it. Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it. Bending : 0.05mm/100mm (0.0020in./3.9370in.) Torsion : 0.1mm/100mm (0.0039in./3.9370in.) NOTE: When assembling the rod without a bearing, there should be no difference.
4. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main bearing 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 M8: 12.7~18.6Nm (1.3~1.9kgf.m, 9.4~13.7lb-ft) + 90~95° M10: 26.5~32.4Nm (2.7~3.3kgf.m, 19.5~23.9lb-ft) + 90~95° NOTE: Tighten the bolts in order. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance 0.004~ 0.022mm (0.0002 ~ 0.0009in.) 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. Crankshaft bore mark location Letters have been stamped on the block as a mark for the each size of the 4 main journal bores. No. 1 journal stamping mark starts from the front of the engine. Use the size marks which are stamped on the block and the crankshaft for the journal bore inner diameter and the journal outer diameter to choose the correct bearings. Discrimination Of Cylinder Block CYLINDER BLOCK SPECIFICATION Class Mark Inside Diameter a A 66.000 ~ 66.006mm (2.5984 ~ 2.5987in.) b B 66.006 ~ 66.012mm (2.5987 ~ 2.5989in.) c C 66.012 ~ 66.018mm (2.5989 ~ 2.5991in.) Crankshaft Journal Mark Location Discrimination Of Crankshaft Discrimination Of Crankshaft CRANKSHAFT SPECIFICATION Class Mark Outside Diameter Of Journal I A 61.994 ~ 62.000mm (2.4407 ~ 2.4409in.) II B 61.988 ~ 61.994mm (2.4405 ~ 2.4407in.) III C 61.982 ~ 61.988mm (2.4402 ~ 2.4405in.) Place Of Identification Mark (Crankshaft Bearing) Discrimination Of Crankshaft Bearing BEARING THICKNESS CHART Class Mark Thickness Of Bearing A Blue 2.007 ~ 2.010mm (0.0790 ~ 0.0791in.) B Black 2.004 ~ 2.007mm (0.0789 ~ 0.0790in.) C - 2.001 ~ 2.004mm (0.0788 ~ 0.0789in.) D Green 1.998 ~ 2.001mm (0.0787 ~ 0.0788in.) E Yellow 1.995 ~ 1.998mm (0.0785 ~ 0.0787in.) Selection Table CRANKSHAFT BORE IDENTIFICATION MARK CHART Crankshaft Bore Identification Mark a (A) b (B) c (C) Crankshaft Identification Mark I (A) E (Yellow) D (Green) C (-) II (B) D (Green) C (-) B (Black) III (C) C (-) B (Black) A (Blue)
5. Check crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard end play 0.07 ~ 0.25mm (0.0028 ~ 0.0098in.) [Limit] 0.3mm (0.0118in.) If the end play is greater than the maximum, replace the center bearing. Thrust bearing thickness 1.925 ~ 1.965mm (0.0758 ~ 0.0774in.)
6. Inspect the main journals and the pin journals of the crankshaft.
7. Using a micrometer, measure the outer diameter of each main journal and pin journal. Main journal diameter: 61.982~ 62.000mm (2.4402 ~ 2.4409in.) Crank pin diameter: 47.982 ~ 48.000mm (1.8891 ~ 1.8898in.)

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1. Remove gasket materials. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Standard: 0.03mm (0.0012in.) or less
4. Inspect cylinder bore diameter Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block or process the piston to be oversized.
5. Inspect the cylinder bore diameter Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions. Standard diameter 86.70 ~ 86.73mm (3.4134 ~ 3.4146in.)
6. Check the cylinder bore size code (A) on the cylinder block. CYLINDER BORE INNER DIAMETER CHART Class Size code Cylinder bore inner diameter A A 86.70 ~ 86.71mm (3.4134 ~ 3.4138in.) B B 86.71 ~ 86.72mm (3.4138 ~ 3.4142in.) C C 86.72 ~ 86.73mm (3.4142 ~ 3.4146in.)
7. Check the piston size code (A) on the piston top face. PISTON OUTER DIAMETER CHART Class Size code Piston outer diameter A A 86.67 ~ 86.68mm (3.4122 ~ 3.4126in.) B B 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) C C 86.69 ~ 86.70mm (3.4130 ~ 3.4134in.)
8. Select the proper piston related to the cylinder bore class. Clearance : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in.)

See also:
• HYDRAULIC POWER STEERING SYSTEM