Kia Rio YB Quiz
Engine Mechanical System

Cylinder block

In this manual: Engine Mechanical System
General Information — 8Maintenance — 31Engine Mechanical System — 44Engine Electrical System — 14Emission Control System — 9Engine Control System/Fuel System — 30Clutch System — 10Manual Transmission — 10Automatic Transmission — 23Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 14Brake System — 22Body (Interior and Exterior) — 115Body Electrical System — 84Heating, Ventilation, and Air Conditioning — 28
25steps
~155min
5/5difficulty
1special tools
0102030405012.79N·mlb·ft
Tightening torque found on this page
Done 0 of 25

Repair Procedures

Disassembly

  1. Remove the engine assembly from the vehicle.

    (See 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.

    (See Cylinder Block - Flywheel)

  4. Install the engine on an engine stand for disassembly.

  5. Remove the timing chain.

    (See Timing System - Timing Chain)

  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 cylinder head assembly.

    (See Cylinder Head Assembly - Cylinder Head)

  9. Remove the water outlet pipe.

    (See Cooling System - Thermostat)

  10. Remove the water temperature control assembly.

    (See Cooling System - Thermostat)

  11. Remove the oil pan and oil screen.

    (See Lubrication System - Oil Pan)

  12. Remove the ladder frame (A).

    Insert the SST blade (09215-3C000) between the cylinder block and the ladder frame. Cut the applied sealant and remove the ladder frame (A).

  13. Remove the piston and connecting rod assembly.

    (Refer to Cylinder Block - Piston and Connecting Rod)

  14. Remove the crankshaft.

    (Refer to Cylinder Block - Crankshaft)

  15. Remove the piston cooling oil jet (A).

Inspection

Cylinder block

  1. Remove the sealing material.

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

  2. Clean the cylinder block.

    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

    Standard: less than 0.05 mm (0.002 in.),

    Less than 0.02 mm (0.0008 in.) / 100 x 100 (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 diameter at points in the axial and transverse directions.

    Standard diameter: 72.00–72.03 mm (2.8346–2.8358 in.)

Installation

  1. Remove the crankshaft.

    (Refer to Cylinder Block - Crankshaft)

  2. Remove the piston and connecting rod assembly.

    (Refer to Cylinder Block - Piston and Connecting Rod)

  3. Install the piston cooling oil jet (A).

    Tightening torque: 8.8–12.7 N·m

  4. Install the oil pan frame.

    1. Using a gasket scraper, remove all old sealing material.

    2. Install a new O-ring (A) on the cylinder block.

    3. Before installing the ladder frame, apply TB1217H liquid sealant to the ladder frame.

      Assemble the part within 5 minutes after the sealant has been applied.

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

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

      Tightening torque: 28.4–32 N·m

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

Test yourself

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