Kia Niro: Cylinder Block / Crankshaft Repair procedures

Disassembly
  

Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Be sure to shut off the high voltage circuit according to the “High Voltage Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.

  

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

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, 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.

1.

Shut off the high voltage circuit.

(Refer to Engine Mechanical System - “High Voltage Shut off Procedure”)

2.

Remove the engine assembly from the vehicle.

(Refer to Engine and Transaxle Assembly - “Engine and Transaxle Assembly”)

3.

Remove the dual clutch transmission

.(Refer to Dual Clutch Transmission (DCT) - "Dual Clutch Transmission Assembly")

4.

Install the engine to engine stand for disassembly.

5.

Remove the intake manifold.

(Refer to Intake and Exhaust System - "Intake Manifold")

6.

Remove the exhaust manifold.

(Refer to Intake and Exhaust System - "Exhaust Manifold")

7.

Remove the hybrid starter generator (HSG).

(Refer to Hybrid Motor System - "Hybrid Starter Generator (HSG)")

8.

Remove the timing chain.

(Refer to Timing System - “Timing Chain”)

9.

Remove the Cylinder head assembly.

(Refer to Cylinder Head Assembly - "Cylinder Head")

10.

Remove the fly wheel.

(Refer to Cylinder Block - "Fly Wheel")

11.

Remove the thermostat.

(Refer to Cooling System - "Thermostat")

12.

Remove the water pump assembly.

(Refer to Cooling System - "Water Pump")

13.

Remove the A/C compressor.

(Refer to Heating, Ventilation Air conditioning -"Compressor")

14.

Remove the oil filter.

(Refer to Lubrication System - "Engine Oil")

15.

Remove the oil screen.

(Refer to Lubrication System - "Oil Pan")

16.

Remove the piston and connecting rod assemblies.

(Refer to Cylinder Block - "Piston and Connecting Rod")

17.

Check the crankshaft main bearing oil clearance.

18.

Check the crankshaft end play.

19.

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

  

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

Inspection

Pilot Bearing

1.

Inspect the pilot bearing.

(1)

Check if the pilot bearing (A) is damaged visually.

(2)

Check if there is noise by rotating the inner shell (A) of pilot bearing.

(3)

If a damage or noise is found, then replace the crankshaft with the pilot bearing.

  

Be sure to replace the crankshaft and pilot bearing together, because crankshaft can be damaged or deformed when removing the pilot bearing.

Crankshaft

1.

Check the crankshaft bearing oil clearance.

(1)

To check main bearing-to-journal oil clearance, remove the lower crankcase and lower bearings.

(2)

Clean each main journal and bearing with a clean shop towel.

(3)

Place one strip of plastigage across each main journal.

(4)

Reinstall the lower crankcase and lower bearings, and then tighten the main bolts.

Tightening torque :

[17.7 - 21.6 N·m (1.8 - 2.2 kgf·m, 13.0 - 15.9 lb·ft) + [88 - 92°]

  

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. Reusing the removed bolts can cause the bolts to break or fail to maintain clamping force.

Do not turn the crankshaft.

(5)

Remove the lower crankcase and lower bearings.

(6)

Measure the width of the plastigage at its widest point.

Oil clearance :

Standard :

0.006 - 0.024 mm (0.0002 - 0.0009 in)

Limit :

0.018 - 0.044 mm (0.0007 - 0.0017 in.)

(7)

If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. Recheck the oil clearance.

  

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

(8)

If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance.

  

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, clean with solvent or detergent instead of scrubbing them with a wire brush or scraper.

Crankshaft Bore Identification Mark

Letters are 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.

Cylinder Block Specifications

Class
Mark
Inside 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 Journal Identification Mark

  

Conform to the stamping order in the direction of the arrow from #1.

Crankshaft Specifications

Class
Mark
Outside Diameter Of Journal
I
1
47.954 - 47.960 mm
(1.8880 - 1.8882 in.)
II
2
47.948 - 47.954mm
(1.8877 - 1.8880 in.)
III
3
47.942 - 47.948 mm
(1.8875 - 1.8877 in.)

Crankshaft Bearing Identification Mark

Crankshaft Bearing Specifications

Class
Mark
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)

(9)

Select a crankshaft bearing using the selection chart.

Selection Chart For Crankshaft Bearings

Assembling Classification Of Bearing
Crankshaft Bore Identification Mark
0(A)
1(B)
2(C)
Crankshaft Identification 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)

2.

Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

If the end play is greater than maximum, replace the center bearing.

End play

Standard: 0.07 - 0.25 mm (0.0028 - 0.0098 in.)

3.

Inspect main journals and crank pins.

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

Main journal diameter :

47.942 - 47.960- mm (1.88748 - 1.88819 in.)

Crank pin diameter :

68.954 - 38.972 mm (1.53362 - 1.53433 in.)

Reassembly
  

Thoroughly clean all parts to be assembled.

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

1.

Check if the pilot bearing (A) is installed in the crankshaft when replacing the crankshaft or short engine.

If being not installed, be sure to install the pilot bearing (A).

  

Be sure to replace the crankshaft and pilot bearing together, because crankshaft can be damaged or deformed when removing the pilot bearing.

Be sure to force on only outer shell of pilot bearing because when forcing on the pilot bearing seal or inner shell, it can be damaged.

Install the pilot bearing to the crank shaft as the illustration below.

Press force :

180 - 920 N (18 - 94 kgf , 40 - 206 lbf)

Press depth :

1.5 - 2.0 mm (0.0591 - 0.0787 in.)

2.

Install the crankshaft main bearings.

  

There is an oil groove for oil holes on upper bearing but not on lower bearing.

(1)

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

3.

Install the thrust bearings.

Install the 2 thrust bearings (A) on both sides of the No.3 journal of the cylinder block with the oil groove facing out.

4.

Place the crankshaft (A) on the cylinder block.

5.

Install the main bearing caps and tighten the cap bolts.

(1)

Apply a light coat of engine oil on the threads of the bolts. Tighten all the bolts with the specified torque in numerical order first, then tighten all the bolts with the specified angle in numerical order.

Tightening torque :

[17.7 - 21.6 N·m (1.8 - 2.2 kgf·m, 13.0 - 15.9 lb·ft)] + [88 - 92°]

  

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.

Be sure to assemble the main bearing caps in correct order.

Install the main bearing cap with the arrow facing the front of the engine.

Tighten all the main bearing cap bolts with the specified torque first, and then retighten all the bolts with the specified angle.

(2)

Check that the crankshaft turns smoothly.

6.

Check the crankshaft end play.

7.

Install the other 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")

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