Kia Picanto JA: Cylinder Block Assembly / Cylinder Block

Kia Picanto (JA) 2017-{YEAR} 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.

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.

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

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")

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")

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