Kia Cee'd Quiz
Engine Mechanical System

Cylinder Block Repair Procedures

In this manual: Engine Mechanical System
General Information — 15Maintenance — 7Engine Mechanical System — 84Engine Electrical System — 49Emission Control System — 22Fuel System — 95Clutch System — 28Manual Transmission — 21Dual Clutch Transmission (DCT) System — 47Drive Shaft and Axle — 20Suspension System — 36Steering — 23Restraints — 39Brake System — 54Body (Interior and Exterior) — 209Body Electrical System — 254Heating, Ventilation, and Air Conditioning — 56
68steps
~408min
5/5difficulty
0102030405021.616N·mlb·ft
Tightening torque found on this page
Done 0 of 68

Removal

This procedure requires engine removal. (Refer to the "Engine and Transaxle Assembly Removal" section in this group.)
  1. MT: Remove the flywheel. (Refer to Cylinder Block - "Flywheel")
  2. AT: Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")
  3. Mount the engine on an engine stand for disassembly.
  4. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  5. Remove the cylinder head. (Refer to Cylinder Head Assembly - "Cylinder Head")
  6. Remove the water jacket spacer. (Refer to Cylinder Block - "Water Jacket Spacer")
  7. Remove the oil level gauge tube.
  8. Remove the knock sensor (A) and the oil filter (B).
  9. Remove the oil pressure sensor (A). (Refer to Lubrication System - "Oil Pressure Switch")
  10. Remove the oil pan. (Refer to Lubrication System - "Oil Pan")
  11. Remove the oil filter (A).
  12. Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")
  13. Remove the ladder frame (A).
  14. Check the connecting rod side clearance.
  15. Remove the connecting rod caps and inspect the oil clearance.
  16. Remove the piston and connecting rod assembly.
    1. Using a ridge reamer, remove all carbon from the upper part of the cylinder.
    2. Push the piston, connecting rod assembly and upper bearing out through the top of the cylinder block.
  17. Remove the main bearing cap and check the oil clearance.
  18. Check the crankshaft end play.
  19. Lift the crankshaft (A) out of the engine, taking care not to damage the journals.
  20. Check the fit between the piston and piston pin. Try moving the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
  21. Remove the piston rings.
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the 2 side rails and the coil spring.
  22. Separate the connecting rod from the piston. Using a press, remove the piston pin from the piston. (Press load: 500 ~ 1500 kg (1102 ~ 3306 lb.))

Inspection

Connecting Rod and Crankshaft

  1. Check the connecting rod side play. Using a feeler gauge, measure the side play while moving the connecting rod back and forth. Standard: 0.10 ~ 0.25 mm (0.0039 ~ 0.0098 in.) Maximum: 0.35 mm (0.0138 in.)
  2. Check the connecting rod bearing oil clearance.
    1. Make sure the alignment marks on the connecting rod and cap are aligned to ensure correct assembly.
    2. Remove the 2 connecting rod cap bolts.
    3. Remove the connecting rod cap and lower bearing.
    4. Clean the crankshaft journal and bearing.
    5. Place a piece of Plastigage on the crankshaft journal.
    6. Install the lower bearing and cap, then tighten the bolts. Do not reuse the bolts. Tightening torque: 17.7 ~ 22 N·m + 88 ~ 92°
    7. Remove the 2 bolts, connecting rod cap and lower bearing.
    8. Measure the Plastigage at its widest point.

      Standard oil clearance: 0.03 ~ 0.05 mm (0.0011 ~ 0.0019 in.)

    9. If the Plastigage reading is too wide or too narrow, remove the upper and lower bearings, then install new bearings with the same color code. Recheck the oil clearance.
    10. If the Plastigage indicates that the clearance is still incorrect, try the next larger or smaller bearing. Location of connecting rod mark
      Connecting Rod Identification
      Mark Connecting Rod Big End
      Inside Diameter
      A, 0 45.000 ~ 45.006 mm (1.7717 ~ 1.7719 in.)
      B, 00 45.006 ~ 45.012 mm (1.7719 ~ 1.7721 in.)
      C, 000 45.012 ~ 45.018 mm (1.7721 ~ 1.7724 in.)

      Location of Crankshaft Pin Diameter Mark
      Crankshaft Journal Diameter Identification
      Mark Crankshaft Journal Outer Diameter
      1 41.972 ~ 41.966 mm (1.6524 ~ 1.6522 in.)
      2 41.966 ~ 41.960 mm (1.6522 ~ 1.6520 in.)
      3 41.960 ~ 41.954 mm (1.6520 ~ 1.6517 in.)

      Location of Connecting Rod Bearing Color
      Connecting Rod Bearing Identification
      Mark Color Connecting Rod Bearing Thickness
      A Blue 1.514 ~ 1.517 mm (0.0596 ~ 0.0597 in.)
      B Black 1.511 ~ 1.514 mm (0.0595 ~ 0.0596 in.)
      C None 1.508 ~ 1.511 mm (0.0594 ~ 0.0595 in.)
      D Green 1.505 ~ 1.508 mm (0.0593 ~ 0.0594 in.)
      E Red 1.502 ~ 1.505 mm (0.0591 ~ 0.0593 in.)
    11. Select the bearing using the selection table. Connecting Rod Bearing Selection Table
      Connecting Rod Mark
      A, 0 B, 00 C, 000
      Crankshaft Journal Mark 1 E
      (Red)      		 D
      (Green)      		 C
      (None)
      2 D
      (Green)      		 C
      (None)      		 B
      (Black)
      3 C
      (None)      		 B
      (Black)      		 A
      (Blue)
  3. Inspect the connecting rods.
    1. When reinstalling, make sure the cylinder numbers stamped on the connecting rod and cap match those noted during removal. When installing a new connecting rod, make sure the bearing locking tabs are on the same side.
    2. Replace the connecting rod if the thrust surfaces at either end are damaged. Also replace the rod if the small end bore inner diameter shows step wear or is heavily roughened.
    3. Using a connecting rod aligner, check the connecting rod for bend and twist. If the measured value is close to the repair limit, correct the rod with a press. Replace any connecting rod that is severely bent or deformed. Allowable connecting rod bend: 0.05 mm/100 mm (0.0020 in./3.94 in.) or less. Allowable connecting rod twist: 0.10 mm/100 mm (0.0039 in./3.94 in.) or less.
  4. Check the crankshaft bearing oil clearance.
    1. To check the main bearing oil clearance, remove the main bearing caps and lower bearings.
    2. Clean each main journal and lower bearing with a clean shop towel.
    3. Place one strip of Plastigage on each main journal.
    4. Install the lower bearings and caps, then tighten the bolts.

      Tightening torque: 17.7 ~ 22 N·m + 88 ~ 92°

    5. Remove the cap and lower bearing again and measure the widest part of the Plastigage. Standard oil clearance No. 1, 2, 3, 4, 5: 0.020 ~ 0.041 mm (0.0007 ~ 0.0016 in.)
    6. If the Plastigage is too wide or too narrow, remove the upper and lower bearings, then install new bearings with the same color code (refer to the Main Bearing Selection Table in this group). Recheck the oil clearance.
    7. If the Plastigage indicates that the clearance is still incorrect, try the next larger or smaller bearing (refer to the Bearing Selection Table in this group). Recheck the oil clearance. Location of the cylinder block main journal bore marks: Letters are stamped on the side of the block as the size mark for each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crankshaft (main journal size marks), to correctly select the bearings.
      Cylinder Block Main Journal Bore Grade
      Mark Cylinder Block Crankshaft Journal Bore
      Inside Diameter
      A 52.000 ~ 52.006 mm (2.0472 ~ 2.0475 in.)
      B 52.006 ~ 52.012 mm (2.0475 ~ 2.0477 in.)
      C 52.012 ~ 52.018 mm (2.0477 ~ 2.0479 in.)

      Location of the mark on the crankshaft main journal
      Crankshaft main journal identification
      Mark Crankshaft Main Journal
      Outside Diameter
      1 47.960 ~ 47.954 mm (1.8882 ~ 1.8879 in.)
      2 47.954 ~ 47.948 mm (1.8879 ~ 1.8877 in.)
      3 47.948 ~ 47.942 mm (1.8877 ~ 1.8875 in.)

      Crankshaft Main Bearing Color Location
      Crankshaft main bearing identification
      Mark Color Thickness of the crankshaft main bearing
      №1, 2, 3, 4, 5
      A Blue 2.026 ~ 2.029 mm (0.0798 ~ 0.0799 in.)
      B Black 2.023 ~ 2.026 mm (0.0796 ~ 0.0798 in.)
      C None 2.020 ~ 2.023 mm (0.0795 ~ 0.0796 in.)
      D Green 2.017 ~ 2.020 mm (0.0794 ~ 0.0795 in.)
      E Red 2.014 ~ 2.017 mm (0.0793 ~ 0.0794 in.)
    8. Select the bearing using the selection table. Crankshaft Main Bearing Selection Table
      Crankshaft Main Journal Bore Mark on Cylinder Block
      A B C
      Crankshaft main journal mark 1 E
      (Red)      		 D
      (Green)      		 C
      (None)
      2 D
      (Green)      		 C
      (None)      		 B
      (Black)
      3 C
      (None)      		 B
      (Black)      		 A
      (Blue)
  5. Check the crankshaft end play. Using a dial indicator, measure the end play by prying the crankshaft forward and backward with a screwdriver. End play Standard: 0.05 ~ 0.25 mm (0.0020 ~ 0.0098 in.) Limit: 0.30 mm (0.0118 in.) If the end play exceeds the limit, replace the center main bearing.
  6. Remove the gasket material. Using a gasket scraper, remove all gasket material from the upper surface of the cylinder block.
  7. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
  8. Inspect the top surface of the cylinder block for flatness. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Cylinder block gasket surface flatness Standard: Overall less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in.) per 100 mm (3.9370 in.) x 100 mm (3.9370 in.) section
  9. Inspect the cylinder bore. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
  10. Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at the points in the axial and transverse directions.

    Standard diameter: 77.00 ~ 77.03 mm (3.0315 ~ 3.0327 in.)

  11. Check the cylinder bore size code on the side of the cylinder block.
    Cylinder Bore Size Classification
    Mark Cylinder Inner Diameter
    A 77.00 ~ 77.01 mm (3.0315 ~ 3.0319 in.)
    B 77.011 ~ 77.020 mm (3.0319 ~ 3.0322 in.)
    C 77.021 ~ 77.030 mm (3.0323 ~ 3.0326 in.)
  12. Check the piston size mark (A) on the piston top surface.
    A: Class S: Type ISG G: Gasoline engine 6: 1.6 L Piston Outside Diameter Identification
    Mark Piston Outer Diameter
    A 76.97 ~ 76.98 mm (3.0303 ~ 3.0307 in.)
    B 76.98 ~ 76.99 mm (3.0307 ~ 3.0311 in.)
    C 76.99 ~ 77.00 mm (3.0311 ~ 3.0315 in.)
  13. Select a piston that matches the cylinder bore size class.

    Piston-to-cylinder clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 in.)

  14. Clean the piston.
    1. Using a gasket scraper, remove carbon deposits from the top of the piston.
    2. Using a ring groove cleaning tool or a broken piston ring, clean the piston ring grooves.
    3. Using solvent and a brush, thoroughly clean the piston.
  15. The standard piston outside diameter measurement is taken 12 mm (0.4724 in.) from the bottom of the piston.

    Standard diameter: 76.97 ~ 77.00 mm (3.0303 ~ 3.0315 in.)

  16. Calculate the difference between the cylinder bore inside diameter and the piston outside diameter.

    Piston-to-cylinder clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 in.)

  17. Check the piston ring side clearance. Using a feeler gauge, measure the clearance between a new piston ring and the ring groove wall. Piston ring side clearance No. 1 ring: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.) No. 2 ring: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.) Oil ring: 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.) Limit No. 1 ring: 0.1 mm (0.0039 in.) No. 2 ring: 0.1 mm (0.0039 in.) Oil ring: 0.2 mm (0.0079 in.)
    If the clearance is greater than the maximum, replace the piston.
  18. Inspect the piston ring end gap. To measure the piston ring end gap, insert the piston ring into the cylinder bore. Position the ring at a right angle to the cylinder wall, carefully pushing it with the piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston rings. If the gap is too large, recheck the cylinder bore inner diameter. If the bore exceeds the service limit, the cylinder block must be bored.
    Piston ring end gap
    Standard
    No. 1 ring: 0.14 ~ 0.28 mm (0.0079 ~ 0.0138 in.)
    No. 2 ring: 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
    Oil ring: 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in.)
    Limit
    No. 1 ring: 0.3 mm (0.0118 in.)
    No. 2 ring: 0.5 mm (0.0197 in.)
    Oil ring: 0.8 mm (0.0315 in.)
  19. Measure the piston pin outer diameter.

    Piston pin diameter: 18.001 ~ 18.006 mm (0.7087 ~ 0.7089 in.)

  20. Measure the clearance between the piston pin and the piston.
    Piston pin-to-piston clearance: 0.010 ~ 0.020 mm (0.0004 ~ 0.0008 in.)
  21. Check the interference between the outer diameter of the piston pin and the inner diameter of the connecting rod small end.
    Piston pin-to-connecting rod interference: -0.032 ~ -0.016 mm (-0.0013 ~ -0.0006 in.)
Cylinder Block Piston and Piston Rings Piston Pins

Installation

  1. Assemble the piston and connecting rod.
    1. For installation, use a hydraulic press.
    2. The front mark on the piston (A) and the front mark on the connecting rod (A) must face the timing chain side of the engine.
  2. Install the piston rings.
    1. Install the oil ring expander spring and the 2 side rails by hand.
    2. Using a piston ring expander, install the 2 compression rings with the code mark facing up.
    3. Position the piston rings so that the ring end gaps are as shown in the illustration.
  3. Install the connecting rod bearings.
    1. Align the bearing tab (A) with the groove of the connecting rod or connecting rod cap (B).
    2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
  4. Install the crankshaft main bearings.
    1. Align the bearing tab with the tab groove of the cylinder block, then insert the five upper bearings (A).
    2. Align the bearing tab with the tab groove in the main bearing cap, then install the 5 lower bearings.
  5. Install the thrust bearings. Install the thrust bearing (A) on the No. 3 cylinder block journal so that the oil grooves face outward.
  6. Install the crankshaft to the cylinder block.
  7. Install the main bearing caps on the cylinder block.
  8. Install the main bearing cap bolts.
    1. Apply a thin coat of engine oil to the threads and under the head of the bearing cap bolts.
    2. Install and evenly tighten the 10 bearing cap bolts in several passes, in the specified sequence.

      Tightening torque: 17.7 ~ 22 N·m + 88 ~ 92°

    3. Make sure the crankshaft rotates smoothly.
  9. Check the crankshaft end play.
  10. Install the piston and connecting rod assembly.
    1. Install the piston ring compressor, make sure the rings are securely in place, then insert the piston into the cylinder and tap it in with the wooden handle of a hammer.
    2. Stop after the ring compressor is released and check the alignment of the connecting rod with the crankshaft journal before pushing the piston into place.
    3. Stop after the ring compressor is released and check the alignment of the connecting rod with the crankshaft journal before pushing the piston into place.

      Tightening torque: 17.7 ~ 22 N·m + 88 ~ 92°

  11. Apply sealant to the oil pan frame.
  12. Install the oil pan frame (A).

    Tightening torque: 18.6 ~ 24 N·m

  13. Install the rear oil seal. (Refer to Cylinder Block - Rear Oil Seal)
  14. Install the oil filter (A). Install a new gasket and the oil filter with 2 bolts.

    Tightening torque: 24.5 ~ 31 N·m

  15. Install the oil pan. (Refer to Lubrication System - "Oil Pan")
  16. Install the oil pressure sensor. (Refer to Lubrication System - Oil Pressure Switch)
  17. Install the knock sensor and the oil filter. (Refer to Lubrication System - Oil Filter)
  18. Install the oil level gauge tube.
  19. Install the water jacket. (Refer to Cylinder Block - Water Jacket Separator)
  20. Install the timing chain. (Refer to Timing System - Timing Chain)
  21. Install the cylinder head. (Refer to Cylinder Head Assembly - Cylinder Head)
  22. Remove the engine stand.
  23. AT: Install the drive plate. (Refer to Cylinder Block - "Drive Plate")
  24. M/T: Install the flywheel. (Refer to Cylinder Block - Flywheel)
  25. Install the engine. (Refer to Engine and Transaxle Assembly - Engine and Transaxle Assembly)

Test yourself

A quick Kia Cee'd quiz: every answer comes with an explanation and a link to the manual page.