Cylinder Block: Overview Kia Rio II рестайлинг

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1. M/T : Remove the fly wheel.
2. A/T : Remove the drive plate.
3. Install the engine to engine stand for disassembly.
4. Remove the timing belt. (Refer to «TIMING SYSTEM»(/kia/rio/ii-2009-2011/remont/mechanical/#timing-system) )
5. Remove the cylinder head. (Refer to «CYLINDER HEAD ASSEMBLY»(ref-378912) )
6. Remove the oil level gauge tube (A).
7. Remove the knock sensor (A).
8. Remove the oil pressure switch (A).
9. Remove the water pump. (Refer to «WATER PUMP»(ref-378914-S10982950022010113000000) )
10. Remove the oil pan (A).
11. Remove the oil screen. Remove the 2bolts (C), oil screen (A) and gasket (B).
12. Check the connecting rod end play. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-378913-S25713882312010113000000) )
13. Remove the connecting rod caps and check oil clearance. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-378913-S25713882312010113000000) )
14. Remove the 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.
15. Remove the front case. (Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-378910) )
16. Remove the rear oil seal case. Remove the 5bolts (B) and rear oil seal case (A).
17. Remove the crankshaft bearing cap and check oil clearance. (Refer to «COMPONENT»(ref-378913-S13790837872010113000000) )
18. Check the crankshaft end play. (Refer to «COMPONENT»(ref-378913-S13790837872010113000000) )
19. 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.
20. 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.
21. Remove the piston rings. Using a piston ring expender, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
22. Remove the connecting rod from the piston. Using a press, remove the piston pin from piston. (Press-in load : 500 ~ 1,500kg (1,102 ~ 3,306lb))

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1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. End play Standard : 0.1 ~ 0.25mm (0.0039 ~ 0.0098in) Maximum : 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 match marks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap nuts. Remove the connecting rod cap and lower bearing. Clean the crankshaft pin journal and bearing. Place a plastigage across the crankshaft pin journal. Reinstall the lower bearing and cap, and tighten the nuts. Tightening torque : 31.4 ~ 34.3N.m (3.2 ~ 3.5kgf.m, 23.1 ~ 25.3lb-ft) NOTE: Do not turn the crankshaft. Remove the 2nuts, connecting rod cap and lower bearing. 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 and lower bearing and then install a new bearings with the same color mark. (Refer to «CONNECTING ROD BEARING SELECTION CHART»(ref-378913-S36816913802010113000000) ) Recheck the oil clearance. CAUTION: Do not file, shim, of 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. (Refer to «CONNECTING ROD BEARING SELECTION CHART»(ref-378913-S36816913802010113000000) ) Recheck the oil clearance. 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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Identification of connecting rod

CONNECTING ROD IDENTIFICATION REFERENCE

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Identification of crankshaft pin journal

CRANKSHAFT PIN JOURNAL IDENTIFICATION REFERENCE

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Identification of connecting rod bearing

CONNECTING ROD BEARING IDENTIFICATION REFERENCE

1. (11) Select the bearing by using selection table. Connecting rod bearing selection table CONNECTING ROD BEARING SELECTION CHART Connecting rod mark ^ b c Crank shaft pin journal mark ^ D (Yellow) C (Green) B (None) b C (Green) B (None) A (Black) c B (None) A (Black) AA (Blue)

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1. 3. Check the connecting rods. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced. Allowable bend of connecting rod : 0.05mm/100mm (0.0020in/3.94in) or less Allowable twist of connecting rod : 0.1mm/100mm (0.0039in/3.94in) or less
2. 4. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings. Clean each main journal and lower bearing with a clean shop towel. Place one strip of plastigage across each main journal. Reinstall the lower bearings and caps, then tighten the bolts. Tightening torque : 53.9 ~ 58.8N.m (5.5 ~ 6.0kgf.m, 39.8 ~ 43.4lb-ft) NOTE: Do not turn the crankshaft. Remove the cap and lower bearing again, and measure the widest part of the plastigage. Standard oil clearance : No. 1, 2, 4, 5 : 0.022 ~ 0.040mm (0.0009 ~ 0.0016in) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to «CRANKSHAFT MAIN BEARING SELECTION CHART»(ref-378913-S28101697822010113000000) ) Recheck the oil clearance. CAUTION: Do not file, shim, or scrape the bearings or the cap to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to «CRANKSHAFT MAIN BEARING SELECTION CHART»(ref-378913-S28101697822010113000000) ) Recheck the oil clearance. 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.

Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.

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Identification of cylinder block crankshaft journal bore

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE IDENTIFICATION REFERENCE

Crankshaft main journal mark location

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Identification of crankshaft main journal

CRANKSHAFT MAIN JOURNAL IDENTIFICATION REFERENCE

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Identification of crankshaft main bearing

CRANKSHAFT MAIN BEARING IDENTIFICATION REFERENCE

1. (8) Select the bearing by using selection table. Crankshaft main bearing selection table CRANKSHAFT MAIN BEARING SELECTION CHART Cylinder block crankshaft journal bore mark ^ b c Crank shaft main journal mark ^ D (Yellow) C (Green) B (None) b C (Green) B (None) A (Black) c B (None) A (Black) AA (Blue)

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1. 5. Check the crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. End play Standard: 0.05 ~ 0.175mm (0.0020 ~ 0.0069in) Limit : 0.20mm (0.0079in) If the end play is greater than maximum, replace the center bearing.
2. 6. Inspect the crankshaft main journals and pin journals. Using a micrometer, measure the diameter of each main journal and pin journal. Main journal diameter : 49.950 ~ 49.968mm (1.9665 ~ 1.9672in) Pin journal diameter : 44.954 ~ 44.972mm (1.7698 ~ 1.7705in)

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1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the 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 : Less than 0.05mm (0.0020in)
4. Inspect the cylinder bore. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect the cylinder bore diameter. Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction. Standard diameter : 1.6 CVVT : 76.50 ~ 76.53mm (3.0118 ~ 3.0130in) 1.4 DOHC : 75.50 ~ 75.53mm (2.9724 ~ 2.9736in)
6. Check the cylinder bore size code on the cylinder block bottom face. Identification of cylinder bore size CYLINDER BORE SIZE IDENTIFICATION REFERENCE Mark Cylinder bore inner diameter A 76.50 ~ 76.51mm (3.0118 ~ 3.0122in) B 76.51 ~ 76.52mm (3.0122 ~ 3.0126in) C 76.52 ~ 76.53mm (3.0126 ~ 3.0130in)
7. Check the piston size mark (A) on the piston top face. Discrimination of piston outer diameter PISTON OUTER DIAMETER Mark Piston outer diameter A 76.47 ~ 76.48mm (3.0106 ~ 3.0110in) B 76.48 ~ 76.49mm (3.0110 ~ 3.0114in) C 76.49 ~ 76.50mm (3.0114 ~ 3.0118in)
8. Select the piston related to cylinder bore class. Piston-to-cylinder clearance : 0.02 ~ 0.04mm (0.0008 ~ 0.0016in)

See also:
• TIMING SYSTEM