Kia Forte: Crankshaft Reassembly - Cylinder Block - Engine Mechanical System - Kia Forte TD 2014-2019 Service ManualKia Forte: Crankshaft Reassembly

Second generation YD (2014-2019) / Kia Forte TD 2014-2019 Service Manual / Engine Mechanical System / Cylinder Block / Crankshaft Reassembly

  
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
1.
Install the crankshaft main bearings.
  
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1)
Align the bearing claw with the groove of the cylinder block, and push in the 5 upper bearings (A).

(2)
Align the bearing claw with the groove of the lower crankcase (B), and push in the 5 lower bearings (A).

2.
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.

3.
Place the crankshaft (A) on the cylinder block.

4.
Apply liquid sealant on the top surface of the lower crankcase.
(1)
Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2)
The sealant locations on the lower crankcase and the cylinder block must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
(3)
Assemble a new rubber gasket (A) on the top of lower crankcase.

(4)
Apply liquid sealant on the bottom of the cylinder block. Continuous bead of sealant should be applied to prevent any path from oil leakage.

Bead width: 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)
Sealant: Threebond 1217H or equivalent

  
Assemble the lower crankcase within 5 minutes after applying sealant.
The engine running or pressure test should not be performed within 30 minutes after assembling the lower crankcase.
Excess sealant on application surface of sealant of following process should be removed before hardening.
If the sealant is applied to the top surface of the lower crankcase, it should be the same position as the cylinder block.
To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
5.
Place the lower crankcase on the cylinder block.
6.
Install the main bearing cap bolts.

Using SST (09221-4A000), install and tighten the 10 main bearing cap bolts, in several passes, in the sequence as shown.

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

  
Always use new crankshaft main bearing cap bolts. Crankshaft main 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.
Do not apply engine oil on the bolt threads to achieve correct torque.
  
The main bearing cap bolts are tightened in 2 progressive steps.
If any of the bearing cap bolts is broken or deformed, replace it.
Be sure to assemble the main bearing cap bolts in correct order.
7.
Install the lower crankcase bolts, in several passes, in sequence as shown.

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

Check that the crankshaft turns smoothly.
8.
Check the crankshaft end play.
9.
Assemble 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 - "Piston and Connecting Rod")
Crankshaft Inspection
1. Check the crankshaft bearing oil clearance. (1) To check main bearing-to-journal oil clearance, remove the lower crankcase and lo ...

Cylinder Block Disassembly
   Use fender covers to avoid damaging painted surfaces. ...

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