Kia Rio: Cylinder Block / Cylinder Block

Kia Rio 2017-2023 YB Service Manual / Engine Mechanical System / Cylinder Block / 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 before removing it.
•

When handling a metal gasket, take care not to fold the gasket or damage the contact 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 pulley so that the No.1 piston is at TDC (Top dead center).
1.

Remove the engine assembly from the vehicle.

(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 - "Flywheel")

4.

Install the engine to engine stand for disassembly.
5.

Remove the timing chain.

(Refer to Timing System - "Timing Chain”)

6.

Remove the intake manifold.

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

7.

Remove the exhaust manifold.

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

8.

Remove the cylinder head assembly.

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

9.

Remove the water pipe.

(Refer to Cooling System - "Thermostat")

10.

Remove the water temperature control assembly.

(Refer to Cooling System - "Thermostat")

11.

Remove the oil pan and oil screen.

(Refer to Lubrication System - "Oil Pan")

12.

Remove the ladder frame (A).

Insert the blade of SST (09215-3C000) between the cylinder block and the ladder frame. Cut off applied sealer and remove the ladder frame (A).
13.

Remove the piston and connecting rod assemblies.

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

14.

Remove the crankshaft.

(Refer to Cylinder Block - "Crankshaft")

15.

Remove the piston cooling oil jet (A).
Inspection

Cylinder Block

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 3.937 in)

4.

Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.

If deep scratchs 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 :

72.00 - 72.03 mm (2.8346 - 2.8358 in)

Reassembly
1.

Remove the crankshaft.

(Refer to Cylinder Block - "Crankshaft")

2.

Remove the piston and connecting rod assemblies.

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

3.

Install the piston cooling oil jet (A).

Tightening torque :

8.8 - 12.7 N·m (0.9 - 1.3 kgf·m, 6.5 - 9.4 lb·ft)

4.

Install the ladder frame.

(1)

Using a gasket scraper, remove all the old packing material.

  

Be careful not to damage the contact surfaces.
(2)

Install the new O-ring (A) to cylinder block.
(3)

Before assembling the ladder frame, the liquid sealant TB1217H should be applied on ladder frame.

The part must be assembled within 5 minutes after the sealant was applied.

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 lb·ft)

5.

Assemble the other parts in the reverse order of disassembly.

    Repair procedures Disassembly    • Use fender covers to avoid damaging painted surfaces.

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