Repair Procedures: Inspection

Check the crankshaft bearing oil clearance.

To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
Clean each main journal and bearing half with a clean shop towel.
Place one strip of plastigage across each main journal.
Reinstall the bearings and caps, and torque the bolts.
Tightening torque:

No. 1 - 8: 49.0 N.m (5.0 kgf.m, 36.2 lb.ft) + 90°

No. 9 - 16: 19.6 N.m (2.0 kgf.m, 14.5 lb.ft)+ 120°

No. 17 - 24: 29.4 - 31.4 N.m (3.0 - 3.2 kgf.m, 21.7 - 23.1 lb.ft)

Fig 1: Crankshaft Main Bearing Cap Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- 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.
- Do not turn the crankshaft.

Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance:

0.023 - 0.041 mm (0.0009 - 0.0016 in.)

Courtesy of KIA MOTORS AMERICA, INC.

If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
NOTE: Do not file, shim, or scrape the bearings or the caps to adjust clearance.

If the plastigage shows that the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.

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

Crankshaft bore mark location

Letters are stamped on the block as a mark for the size of each of the 4 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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Identification of Cylinder Block

CYLINDER BLOCK SPECIFICATION

Class	Mark	Inside Diameter
a	A	73.500 - 73.506 mm (2.8937 - 2.8939 in.)
b	B	73.506 - 73.512 mm (2.8939 - 2.8942 in.)
c	C	73.512-73.518 mm (2.8942 - 2.8944 in.)

Crankshaft Journal Mark Location

Identification of Crankshaft

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Identification of Crankshaft

CRANKSHAFT SPECIFICATION

Class	Mark	Outside Diameter of Journal
I	1 or A	68.954 - 68.960 mm (2.7147 - 2.7150 in.)
II	2 or B	68.948 - 68.954 mm (2.7145 - 2.7147 in.)
III	3 or C	68.942 - 68.948 mm (2.7142 - 2.7145 in.)

Place of Identification Mark (Crankshaft Bearing)

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Identification of Crankshaft Bearing

CRANKSHAFT BEARING SPECIFICATION

Class	Mark
E	Blue
D	Black
C	Red
B	Green
A	Yellow

Selection

		Crankshaft Bore Identification Mark
		a(A)	b(B)	c(C)
Crankshaft Identification Mark	1 or A	A (Yellow)	B (Green)	C (Red)
	2 or B	B (Green)	C (Red)	D (Black)
	3 or C	C (Red)	D (Black)	E (Blue)

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

Standard end play:

0.10 - 0.28 mm (0.0039 - 0.0110 in.)

Courtesy of KIA MOTORS AMERICA, INC.

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness:

2.41 - 2.45 mm (0.0949 - 0.0964 in.)
Inspect main journals and crank pins
Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter:

68.942 - 68.960 mm (2.7142 - 2.7149 in.)

Crank pin diameter:

54.954 - 54.972 mm (2.1635 - 2.1642 in.)

Courtesy of KIA MOTORS AMERICA, INC.