Kia Picanto JA Quiz
Engine Mechanical System

Cylinder block

In this manual: Engine Mechanical System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
36steps
~221min
5/5difficulty
1special tools
0102030405012.79N·mlb·ft
Tightening torque found on this page
Done 0 of 36

Repair Procedures

Disassembly

  1. Remove the engine and transaxle assembly. (Refer to Engine and Transaxle Assembly - "Engine and Transaxle Assembly")
  2. Remove the transaxle assembly from the engine assembly. (See Manual Transaxle System - Manual Transaxle)
  3. Remove the flywheel. (Refer to Cylinder Block Assembly - "Flywheel")
  4. Remove the rear oil seal. (Refer to Cylinder Block Assembly - "Rear Oil Seal")
  5. Install the engine assembly on an engine stand for disassembly.
  6. Remove the cylinder head cover. (Refer to Cylinder Head Assembly - Cylinder Head Cover)
  7. Remove the thermostat housing. (Refer to Cooling System - "Thermostat")
  8. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  9. Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
  10. Remove the turbocharger manifold module. (Refer to Intake and Exhaust System - "Turbocharger Manifold Module")
  11. Remove the cylinder head. (Refer to Cylinder Head Assembly - "Cylinder Head")
  12. Remove the oil pan and oil screen. (Refer to Lubrication System - "Oil Pan")
  13. Remove the ladder frame (A). Insert a SST (09215-3C000) blade between the cylinder block and the ladder frame and cut the applied sealant. Then remove the ladder frame.
  14. Inspect the connecting rod side clearance. (See Cylinder Block Assembly - Piston and Connecting Rod)
  15. Check the connecting rod cap oil clearance. (Refer to Cylinder Block Assembly - Piston and Connecting Rod)
  16. Remove the piston and connecting rod assembly. (See Cylinder Block Assembly - Piston and Connecting Rod)
  17. Inspect the main bearing oil clearance. (See Cylinder Block Assembly - Crankshaft)
  18. Inspect the crankshaft end play. (See Cylinder Block Assembly - Crankshaft)
  19. Remove the crankshaft. (See Cylinder Block Assembly - Crankshaft)
  20. Remove the water jacket spacer. (Refer to Cylinder Block - Water Jacket Spacer)
  21. Remove the oil jet (A).

Inspection

  1. Remove the gasket material. Using a gasket scraper, remove all gasket material from the upper surface of the cylinder block.
  2. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
  3. Inspect the cylinder block upper surface for flatness. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head gasket for distortion. Cylinder block gasket surface flatness. Standard: less than 0.05 mm (0.002 in.). Limit: less than 0.02 mm (0.0008 in.) / 100 x 100 mm (3.937 x 3.937 in.)
  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 bore diameter at the positions in both the axial and transverse directions.

    Standard diameter: 71.00–71.03 mm (2.7952–2.7964 in.)

Installation

  1. Install the oil jet (A).

    Tightening torque: 8.8–12.7 N·m

  2. Install the water jacket spacer. (Refer to Cylinder Block - Water Jacket Spacer)
  3. Install the crankshaft. (Refer to Cylinder Block Assembly - Crankshaft)
  4. Inspect the crankshaft end play. (See Cylinder Block Assembly - Crankshaft)
  5. Inspect the main bearing oil clearance. (See Cylinder Block Assembly - Crankshaft)
  6. Install the piston and connecting rod assembly. (Refer to Cylinder Block Assembly - Piston and Connecting Rod)
  7. Check the connecting rod cap oil clearance. (Refer to Cylinder Block Assembly - Piston and Connecting Rod)
  8. Inspect the connecting rod side clearance. (See Cylinder Block Assembly - Piston and Connecting Rod)
  9. Install the oil pan frame.
    1. Using a gasket scraper, remove all old sealing material.
    2. Install the O-ring (A) on the cylinder block.
    3. Before assembling the ladder frame, apply liquid sealant to the ladder frame. Assemble the parts within 5 minutes after applying the sealant.

      Bead width: 2.5–3.5 mm (0.1–0.14 in.)

    4. Install and evenly tighten the ladder frame bolts in several passes.

      Tightening torque: 28.4–32 N·m

  10. Assemble the remaining components in the reverse order of removal.

Test yourself

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