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Home >> Kia >> 2021 >> Rio S, 4D Hatchback >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block Assembly >> Crankshaft >> Repair Procedures >> Reassembly

Repair Procedures: Reassembly

NOTE:
  • Thoroughly clean all parts to assembled.
  • Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
  1. Install the crankshaft position sensor wheel (A).

    Tightening torque: 

    12.7 - 13.7 N.m (1.3 - 1.4 kgf.m, 9.4 - 10.1 lb.ft)

    G13704111Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the crankshaft main bearings.

    Information 

    Upper bearings have an oil groove of oil holes; Lower bearings do not.

    NOTE: When installing the crankshaft upper bearing, select the correct bearing for each journal.
    [Crankshaft upper bearing (No. 2, No. 4 journal)] 
    G13704112Courtesy of KIA MOTORS AMERICA, INC.

    [Crankshaft upper bearing (No. 1, No. 3, No. 5 journal)] 
    G13704113Courtesy of KIA MOTORS AMERICA, INC.
    1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings (A).
      G13704114Courtesy of KIA MOTORS AMERICA, INC.
    2. Align the bearing claw with the claw groove of the lower crankcase bearing cap, and push in the 5 lower bearings (A).
      G13704115Courtesy of KIA MOTORS AMERICA, INC.
    3. Apply a coat of engine oil after assembling the main bearings.
  3. Install the thrust bearings (No. 4 journal).

    Install the 2 thrust bearings (A) on both sides of the No. 4 journal of the cylinder block with the oil groove facing out.

    G13704116Courtesy of KIA MOTORS AMERICA, INC.
  4. Place the crankshaft (A) on the cylinder block.
    G13704117Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the lower crankcase.
    1. Get rid of hardened sealant, foreign substance, oil, dust, moisture, etc. on the liquid gasket sealing surface of lower crankcase. Wipe the sealing surface with clean cloth after spray cleaner.
    2. Install the new O-ring (A).
      G13704118Courtesy of KIA MOTORS AMERICA, INC.
    3. Apply liquid gasket to the mating surface of lower crankcase.

      Bead width  : 2.5 - 3.5 mm (0.0984 - 0.1378 in)

      Sealant  : THREE-BOND 1217H or LOCTITE 5900H

      G13704119Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Assemble the lower crankcase within 5 minutes after applying sealant.
    4. Install and tighten the crankshaft bearing cap bolts, in several passes, in the sequence as shown.

      Tightening torque: 

      17.7-21.6 N.m (1.8-2.2 kgf.m, 13.0-15.9 lb.ft) + (108 - 112°)

      Fig 1: Crankshaft Bearing Caps Bolts Tightening Sequence
      G13704120Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Always use new crankshaft bearing cap bolts. Crankshaft bearing cap bolts are toque-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. Install and tighten the lower crankcase mounting bolts, in several passes, in the sequence as shown.

      Tightening torque: 

      18.6-23.5 N.m (1.9-2.4 kgf.m, 13.7-17.4 lb.ft)

      Fig 2: Lower Crankcase Mounting Bolts Tightening Sequence
      G13704121Courtesy of KIA MOTORS AMERICA, INC.
      G13704122Courtesy of KIA MOTORS AMERICA, INC.
    6. Install the rear cap (A).
      G13704123Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Cylinder block installation surface and rear cap installation surface have to be corresponded when rear cap installation.
      G13704124Courtesy of KIA MOTORS AMERICA, INC.
    7. Check that the crankshaft turns smoothly.
  6. Check the crankshaft end play.
  7. Install the piston and connecting rod assemblies.

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

  8. Assemble the other parts in the reverse order of disassembly.

    Information 

    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.

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