Kia Picanto: Cylinder Block Assembly / Cylinder Block

Kia Picanto JA 2017-2022 Service & Repair Manual / Engine Mechanical System / Cylinder Block Assembly / Cylinder Block

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 (20°C [68°F]) before removing it.
When handling a metal gasket, be careful not to fold the gasket or damage the contacting 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 damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.
1.
Remove the engine and transaxle assembly.
(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 Assembly - "Flywheel")
4.
Remove the rear oil seal.
(Refer to Cylinder Block Assembly - "Rear Oil Seal")
5.
Install the engine assembly to engine stand for disassembly.
6.
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - “Cylinder Head Cover”)
7.
Remove the thermostat housing.
(Refer to Cooling System - “Thermostat”)
8.
Remove the timing chain.
(Refer to Timing System - “Timing Chain”)
9.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
10.
Remove the turbo manifold module.
(Refer to Intake and Exhaust System - "Turbo Manifold Module")
11.
Remove the cylinder head.
(Refer to Cylinder Head Assembly - “Cylinder Head”)
12.
Remove the oil pan and the oil screen.
(Refer to Lubrication System - “Oil pan”)
13.
Remove the ladder frame (A).
Insert the blade of SST (09215-3C000) between the cylinder block and the ladder frame and cut out applied sealer. Then, remove the ladder frame.

   
Insert the SST between the cylinder block and the ladder frame by tapping it with a plastic hammer in the direction of (1) arrow.
After tapping the SST with a plastic hammer along the direction of (2) arrow around more than 2/3 edge of the ladder frame, remove it from the cylinder block.
Do not turn over the SST abruptly without tapping as it may damage the SST.
Be careful not to damage the contacting surfaces of cylinder block and ladder frame.

14.
Check the connecting rod side clearance.
(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")
15.
Check the connecting rod cap oil clearance.
(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")
16.
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
17.
Check the main bearing oil clearance.
(Refer to Cylinder Block Assembly - "Crankshaft")
18.
Check the crankshaft end play.
(Refer to Cylinder Block Assembly - "Crankshaft")
19.
Remove the crankshaft.
(Refer to Cylinder Block Assembly - "Crankshaft")
20.
Remove the water jacket insert.
(Refer to Cylinder block - "Water Jacket Insert")
21.
Remove the oil jet (A).

Inspection
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 the 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 0.05 mm (0.002 in),
Less than 0.02 mm (0.0008 in) / 100 x 100 (3.937 x 3.937in)

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 :
71.00 - 71.03 mm (2.7952 - 2.7964 in)

Reassembly
1.
Install the oil jet (A).
Tightening torque :
8.8 - 12.7 N·m (0.9 - 1.3 kgf·m, 6.5 - 9.4 lb·ft)

2.
Install the water jacket insert.
(Refer to Cylinder block - "Water Jacket Insert")
3.
Install the crankshaft.
(Refer to Cylinder Block Assembly - "Crankshaft")
4.
Check the crankshaft end play.
(Refer to Cylinder Block Assembly - "Crankshaft")
5.
Check the main bearing oil clearance.
(Refer to Cylinder Block Assembly - "Crankshaft")
6.
Install the piston and connecting rod assemblies.
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
7.
Check the connecting rod cap oil clearance.
(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")
8.
Check the connecting rod side clearance.
(Refer to Cylinder Block Assembly - "Piston And Connecting Rod")
9.
Install the ladder frame.
(1)
Using a gasket scraper, remove all the old packing material.
   
Be careful not to damage the contacting surfaces.
(2)
Install the O-ring (A) to cylinder block.

(3)
Before assembling the ladder frame, the liquid sealant should be applied on ladder frame.
Assemble the part within 5 minutes of applying sealant.
Bead width : 2.5 - 3.5 mm (0.1 - 0.14 in)

(4)
Install and uniformly tighten the ladder frame bolts in several passes.
Tightening torque :
28.4 - 32.4 N·m (2.9 - 3.3 kgf·m, 21.0 - 23.9.4 lb·ft)

10.
Assemble the remaining parts in the reverse order of disassembly.
   
In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block.
Crankshaft main bearing selection
(Refer to Cylinder Block Assembly - "Crankshaft")
Piston selection
(Refer to Cylinder Block Assembly - "Piston and Connecting Rod")
Crankshaft
Repair procedures Disassembly    • Use fender covers to avoid damaging painted surfaces.• To avoid damaging the ...

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