Kia Picanto JA: Cylinder Block Assembly / Crankshaft

Kia Picanto (JA) 2017-{YEAR} Service & Repair Manual / Engine Mechanical System / Cylinder Block Assembly / 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 (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. (Refer to Cylinder Block - “Cylinder Block”)

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

15.	Check the main bearing oil clearance.

16.	Remove the main bearing caps (A).

17.	Check the crankshaft end play.

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

•	Arrange the main bearings and thrust bearings in the correct order.

•	Keep the main bearing caps with their bearings assembled together.

Inspection

Check the crankshaft main 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 in the following method by tightening to the specified torque.

Tightening torque :

17.7 - 21.6 N·m (1.8 - 2.2 kgf·m, 13.0 - 15.9 lb·ft) + 103 - 105°

•	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.

Standard oil clearance :

0.006 - 0.024 mm (0.0002 - 0.0009 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 that 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 due to an accumulation of dirt and dust, instead of scrubbing them with a wire brush or scraper, clean with solvent or detergent only.

Cylinder block crankshaft journal bore mark location

Letters are stamped on the front face of block to mark 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.

Discrimination Of Cylinder Block Crankshaft Journal Bore

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

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal

Class	Mark	Crankshaft main journal outer diameter
I	1	47.954 - 47.960mm (1.8880 - 1.8882in)
II	2	47.948 - 47.954mm (1.8877 - 1.8880in)
III	3	47.942 - 47.948mm (1.8875 - 1.8877in)

Crankshaft Main Bearing Mark Location

Discrimination Of Crankshaft Main Bearing

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

(8)

Select the bearing from the 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 (1.8875 - 1.8882 in)

Pin journal diameter :

38.954 - 38.972 mm (1.5336 - 1.5343 in)

Reassembly

•	Thoroughly clean all parts to be assembled.

•	Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.

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, and push in the 4 upper bearings (A).

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

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.

•	Replace any broken or deformed bearing cap bolts.

(1)

Install and tighten the 8 main bearing cap bolts, in several passes, in the sequence shown.

Tightening torque :

17.7 - 21.6 N·m (1.8 - 2.2 kgf·m, 13.0 - 15.9 lb·ft) + 103 - 105°

(2)	Check that the crankshaft turns smoothly.

4.	Check the crankshaft end play.

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

In case the crankshaft is replaced with a new one, select the proper connecting rod bearing according to the pin journal mark on the crankshaft.

•	Connecting rod bearing selection (Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

Piston and Connecting Rod

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