Kia Picanto (JA): Cylinder Block Assembly / Cylinder Block

Kia Picanto (JA) 2017-2026 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")

    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.

    Components and components location Components 1. Cylinder head gasket 2. Cylinder head 3. Intake oil control valve (OCV) 4. Exhaust oil control valve (OCV) 5.

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