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Home › Kia › 2021 › Forte EX › Repair and Diagnosis › Engine Mechanical › Mechanical › Cylinder Block - 2.0L › Crankshaft › Repair Procedures › Disassembly › Notes

Repair Procedures: Disassembly: Notes

NOTE:
  • 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, 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.

Information 

  1. Remove the engine assembly from the vehicle.

    (Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")

  2. Remove the manual transaxle assembly from the engine assembly.

    (Refer to Manual Transaxle System - "MANUAL TRANSAXLE ")

    Remove the intelligent variable transmission assembly from the engine assembly.

    (Refer to Intelligent Variable Transmission (IVT) System - "INTELLIGENT VARIABLE TRANSMISSION (IVT) ")

  3. Intelligent variable transmission: Remove the drive plate

    (Refer to Cylinder Block - "DRIVE PLATE ")

    Manual transaxle: Remove the flywheel.

    (Refer to Cylinder Block - "FLY WHEEL ")

  4. Remove the rear oil seal.

    (Refer to Cylinder Block - "REAR OIL SEAL ")

  5. Install the engine to engine stand for disassembly.
  6. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  7. Remove the water pump assembly.

    (Refer to Cooling System - "WATER PUMP ")

  8. Remove the water inlet fitting and the electric thermostat (ECT).

    (Refer to Cooling System - "ELECTRIC THERMOSTAT (ECT) ")

  9. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  10. Remove the A/C compressor.

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

  11. Remove the exhaust manifold.

    (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

  12. Remove the cylinder head assembly.

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

  13. Remove the oil filter.

    (Refer to Lubrication System - "ENGINE OIL ")

  14. Remove the oil screen.

    (Refer to Lubrication System - "OIL PAN ")

  15. Remove the piston and connecting rod assemblies.

    (Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")

  16. Check the crankshaft bearing oil clearance.
  17. Remove the lower crankcase (A).
    1. Remove the lower crankcase mounting bolts.
      G13306601Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the main bearing cap bolts.
      G13306602Courtesy of KIA MOTORS AMERICA, INC.
  18. Check the crankshaft end play.
  19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    G13306603Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Arrange the main bearings and thrust bearings in the correct order.

Inspection 

  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 

      1st step:

      27.5 - 31.4 N.m (2.8 - 3.2 kgf-m, 20.3 - 23.1 lb-ft)

      2nd step: 120 - 125°

      NOTE:
      • 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 lower crankcase and lower bearings.
    6. Measure the width of the plastigage at its widest point.

      Oil clearance: 

      0.016 - 0.034 mm (0.00063 - 0.00134 in.)

      G13306604Courtesy of KIA MOTORS AMERICA, INC.
    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.
      NOTE: 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.
      NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
      NOTE: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

    Crankshaft Bore Identification Mark 

    G13306605Courtesy of KIA MOTORS AMERICA, INC.

    Letters have 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.

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