Kia Forte BD Quiz
Engine Mechanical System

Cylinder block

In this manual: Engine Mechanical System
General Information — 8Maintenance — 32Engine Mechanical System — 47Engine Electrical System — 17Emission Control System — 10Engine Control System/Fuel System — 32Clutch System — 11Manual Transmission — 11DCT (Dual Clutch Transmission) System — 16Drive Shaft and Axle — 8Suspension System — 26Steering — 9Restraints — 11Brake System — 27Body (Interior and Exterior) — 119Body Electrical System — 98Heating, Ventilation, and Air Conditioning — 27
27steps
~162min
4/5difficulty
Done 0 of 27

Repair Procedures

Disassembly

  1. Remove the engine and transaxle assembly from the vehicle.

    (See Engine and Transaxle Assembly - Engine and Transaxle Installation)

  2. Remove the transaxle assembly.

    Manual Transaxle System:

    (See Manual Transaxle System - Manual Transaxle)

    DCT (Dual Clutch Transmission) System:

    (See DCT (Dual Clutch Transmission) System - DCT (Dual Clutch Transmission))

  3. 3. Remove the flywheel.

    (See Cylinder Block - Flywheel)

  4. Remove the rear oil seal.

    (See Cylinder Block Assembly - Rear Oil Seal)

  5. Install the engine assembly on an engine stand for disassembly.

  6. Remove the intake manifold.

    (See Intake and Exhaust System - Intake Manifold)

  7. Remove the exhaust manifold.

    (See Intake and Exhaust System - Exhaust Manifold)

  8. Remove the timing chain.

    (See Timing System - Timing Chain)

  9. Remove the cylinder head assembly.

    (See Cylinder Head Assembly - Cylinder Head)

  10. Remove the oil cooler.

    (See Lubrication System - Oil Cooler)

  11. Remove the oil pressure sensor.

    (See Lubrication System - Oil Pressure Relief Valve)

  12. Remove the crankshaft position sensor.

    (See Engine Control Module/Fuel System - Crankshaft Position Sensor (CKPS))

  13. Remove the oil pan and oil screen.

    (See Lubrication System - Oil Pan)

  14. Remove the ladder frame.

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

  15. Check the connecting rod side clearance.

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

  16. Check the oil clearance of the connecting rod bearing cap.

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

  17. Remove the piston and connecting rod assembly.

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

  18. Check the oil clearance of the main bearing.

    (See Cylinder Block Assembly - Crankshaft)

  19. Check the crankshaft end play.

    (See Cylinder Block Assembly - Crankshaft)

  20. Remove the crankshaft.

    (See Cylinder Block Assembly - Crankshaft)

  21. Remove the water inlet pipe and thermostat.

    (See Cooling System - Thermostat)

  22. Remove the knock sensor.

    (See Engine Control Module/Fuel System - Knock Sensor (KS)).

Inspection

  1. Using a gasket scraper, remove all gasket material from the top surface of the cylinder block.

  2. 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 straightedge and feeler gauge, measure the cylinder head gasket contact surface for warpage.

    Cylinder block gasket surface flatness:

    Total area less than 0.05 mm (0.0020 in.)

    Less than 0.02 mm (0.0008 in.) for a 100 mm x 100 mm (3.9370 x 3.9370 in.) area

  4. Inspect the cylinder bore.

    Visually check the cylinder for vertical scratches.

    If deep scratches are found, replace the cylinder block.

  5. Check the cylinder bore diameter.

    Using a cylinder gauge, measure the cylinder diameter at points in the axial and transverse directions.

    Cylinder bore diameter: 77.00–77.03 mm (3.0315–3.0327 in.)

Installation

  1. Install in the reverse order of removal.

Test yourself

A quick Kia Forte BD quiz: every answer comes with an explanation and a link to the manual page.