Kia Rio: Cylinder Block / Crankshaft

Kia Rio 2017-2024 YB Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft

Repair procedures

Disassembly

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.

•	When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

•	To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

•	Mark all wiring and hoses to avoid misconnection.

•	Turn the crankshaft pulley so that the No.1 piston is at TDC (Top dead center).

1.	Remove the engine assembly from the vehicle. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly”)

2.	Remove the transaxle assembly from the engine assembly. (Refer to Manual Transaxle System - "Manual Transaxle")

3.	Remove the flywheel. (Refer to Cylinder Block - "Flywheel")

4.	Install the engine to engine stand for disassembly.

5.	Remove the timing chain. (Refer to Timing System - "Timing Chain”)

6.	Remove the intake manifold. (Refer to Intake and Exhaust System - "Intake Manifold")

7.	Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")

8.	Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")

9.	Remove the water pipe. (Refer to Cooling System - "Thermostat")

10.	Remove the water temperature control assembly. (Refer to Cooling System - "Thermostat")

11.	Remove the oil pan and oil screen. (Refer to Lubrication System - "Oil Pan")

12.	Remove the ladder frame. (Refer to Cylinder Block - "Cylinder Block")

13.	Remove the piston and connecting rod assemblies. (Refer to Cylinder Block - "Piston and Connecting Rod")

14.	Remove the main bearing caps (A) and check oil clearance.

15.	Check the crankshaft end play.

16.

Lift the crankshaft (A) out of engine, being careful not to damage journals.

Arrange the main bearings and center bearings in the correct order.

Inspection

Check the connecting rod bearing oil clearance.

(1)	To check main bearing-to-journal oil clearance, remove the main bearings.

(2)	Clean each main journal and bearing half with a clean shop tower.

(3)	Place one strip of plastigage across each main journal.

(4)

Reinstall the bearings and bolts as following method with specified torque. In the sequence.

Tightening torque :

17.7 - 21.6 N·m (1.8 - 2.0 kgf·m, 13.0 - 15.9 lb·ft) + 88 - 92°

•	Do not turn the crankshaft.

•	Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

(5)

Remove the cap and bearing again, and measure the widest part of the plastigage.

Main bearing oil clearance :

0.006 - 0.024 mm (0.0002 - 0.0009 in)

Main bearing oil clearance include big hole expension deformation :

0.021 - 0.039 mm (0.0008 - 0.0015 in)

(6)

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.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7)

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.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

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.

Cylinder block crankshaft journal bore mark location

Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.

Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.

Grade	Mark	Cylinder Block Crankshaft journal Bore Inner Diameter
a	A	52.000 - 52.006 mm (2.0472 ~ 2.0475 in)
b	B	52.006 - 52.012 mm (2.0475 - 2.0477 in)
c	C	52.012 - 52.018 mm (2.0477 - 2.0480 in)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal

Class	Mark	Crankshaft main journal outer diameter
I	1	47.954 - 47.960 mm (1.8879 - 1.8881 in)
II	2	47.948 - 47.954 mm (1.8877 - 1.8879 in)
III	3	47.942 - 47.948 mm (1.8874 - 1.8877 in)

Crankshaft Main Bearing Mark Location

Mark	Color	Crankshaft Main Bearing Thickness
A	Blue	2.026 - 2.029 mm (0.0797 - 0.0798 in)
B	Black	2.023 - 2.026 mm (0.0796 - 0.0797 in)
C	None	2.020 - 2.023 mm (0.0795 - 0.0796 in)
D	Green	2.017 - 2.020 mm (0.0794 - 0.0795 in)
E	Yellow	2.014 - 2.017 mm (0.0793 - 0.0794 in)

(8)

Select the bearing by using selection table.

Crankshaft Main Bearing Selection Table

Crankshaft Main Bearing		Cylinder Block Crankshaft Journal Bore Mark
Crankshaft Main Bearing		a(A)	b(B)	c(C)
Crank shaft main journal mark	I(1)	E(Yellow)	D(Green)	C(None)
	II(2)	D(Green)	C(None)	B(Black)
	III(3)	C(None)	B(Black)	A(Blue)

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 - 0.25 mm ( 0.0028 - 0.0098 in)

If the end play is greater than maximum, replace the center bearings as a set.

Thrust bearing thickness :

1.925 - 1.965 mm (0.0757 - 0.0774 in)

Crankshaft end play :

0.07 - 0.25 mm (0.0028 - 0.0098 in)

Inspect the crankshaft main journals and pin journals.

Using a micrometer, measure the diameter of each main journal and pin journal.

Main journal diameter :

47.942 - 47.960 mm (1.8874 - 1.8881 in)

Pin journal diameter :

38.954 - 38.972 mm (1.5336 - 1.5343 in)

Reassembly

Install the crankshaft main bearings.

Upper bearings have an oil groove of oil holes; Lower bearings do not.

(1)	Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings (A).

(2)	Install the thrust bearings. Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

(3)	Install the crankshaft lower main bearing. Align the bearing claw with the groove of the crankshaft lower bearing and crankshaft main bearing cap.

2.	Place the crankshaft (A) on the cylinder block.

Install the main bearing cap (A).

•	Always use new crankshaft main bearing cap bolts. Crankshaft main bearing cap bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

•	If any of the bearing cap bolts are broken or deformed, replace it.

(1)	Apply a light coat of engine oil on the threads and under the bearing cap bolts.

(2)

Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.

Tightening torque :

17.7 - 21.6 N·m (1.8 - 2.0 kgf·m, 13.0 - 15.9 lb·ft) + 88 - 92°

(3)	Check that the crankshaft turns smoothly.

4.	Check the crankshaft end play.

5.	Assemble the other parts in the reverse order of disassembly.

Piston and Connecting Rod

Repair procedures Disassembly • Use fender covers to avoid damaging painted surfaces. ...

Cylinder Block

Repair procedures Disassembly • Use fender covers to avoid damaging painted surfaces. ...

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