Kia Rio: Inspection

Connecting Rod And Crankshaft

Check the connecting rod end play.

Using feeler gauge, measure the end play while moving the connecting rod back and forth.

End play

Standard : 0.10 ~ 0.25mm (0.0039 ~ 0.0098in)

Maximum : 0.35mm (0.0138in)

A.	If out-of-tolerance, install a new connecting rod.

B.	If still out-of-tolerance after connecting rod replacement, replace the crankshaft.

Check the connecting rod bearing oil clearance.

(1)	Check the match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2)	Remove the 2 connecting rod cap bolts.

(3)	Remove the connecting rod cap and lower bearing.

(4)	Clean the crankshaft pin journal and bearing.

(5)	Place a plastigage across the crankshaft pin journal.

(6)

Reinstall the lower bearing and cap, and tighten the bolts. Do not reuse the bolts.

Tightening torque :

17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft) + 88 ~ 92°

•	Always use new connecting rod cap bolts. Connecting rod 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 turn the crankshaft.

(7)	Remove the 2 bolts, connecting rod cap and lower bearing .

(8)

Measure the plastigage at its widest point.

Standard oil clearance

0.032 ~ 0.052mm (0.0013 ~ 0.0020in)

(9)

If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.

Recheck the oil clearance.

Do not file, shim, of scrape the bearings or the caps to adjust clearance.

(10)

If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing.

Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and restart over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Connecting Rod Mark Location

Discrimination Of Connecting Rod

Mark	Connecting rod big-end inner diameter
A, 0	45.000 ~ 45.006mm (1.7717 ~ 1.7719in)
B, 00	45.006 ~ 45.012mm (1.7719 ~ 1.7721in)
C, 000	45.012 ~ 45.018mm (1.7721 ~ 1.7724in)

Crankshaft Pin Diameter Mark Location

Discrimination Of Crankshaft Pin Diameter

Mark	Crankshaft pin outer diameter
1	41.972 ~ 41.966mm (1.6524 ~ 1.6522in)
2	41.966 ~ 41.960mm (1.6522 ~ 1.6520in)
3	41.960 ~ 41.954mm (1.6520 ~ 1.6517in)

Connecting Rod Bearing Color Location

Discrimination Of Connecting Rod Bearing

Mark	Color	Connecting rod bearing thickness
A	Blue	1.514 ~ 1.517mm (0.0596 ~ 0.0597in)
B	Black	1.511 ~ 1.514mm (0.0595 ~ 0.0596in)
C	None	1.508 ~ 1.511mm (0.0594 ~ 0.0595in)
D	Green	1.505 ~ 1.508mm (0.0593 ~ 0.0594in)
E	Red	1.502 ~ 1.505mm (0.0591 ~ 0.0593in)

(11)

Select the bearing by using selection table.

Connecting Rod Bearing Selection Table

		Connecting rod mark
		A, 0	B, 00	C, 000
Crank shaft pin journal mark	1	E (Red)	D (Green)	C (None)
	2	D (Green)	C (None)	B (Black)
	3	C (None)	B (Black)	A (Blue)

Check the connecting rods.

(1)	When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.

(2)	Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.

(3)

Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.

Allowable bend of connecting rod :

0.05mm / 100mm (0.0020in / 3.94in ) or less

Allowable twist of connecting rod :

0.10mm / 100mm (0.0039in / 3.94in) or less

When the connecting rods installed without bearings, there should be no difference on side surface.

Check the crankshaft bearing oil clearance.

(1)	To check main bearing-to-journal 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 across each main journal.

(4)

Reinstall the lower bearings and caps, then tighten the bolts.

Tightening torque :

17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

•	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 turn the crankshaft.

(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 : 0.021 ~ 0.042mm (0.0008 ~ 0.0017in)

(6)

If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to crankshaft main bearing selection table in this Group).

Recheck the oil clearance.

Do not file, shim, or scrape the bearings or the cap to adjust clearance.

(7)

If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft main bearing selection table in this Group).

Recheck the oil clearance.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

Cylinder block crankshaft journal bore mark location

Letters have been stamped on the side surface of the block as a mark for the size of each of the 5 main journal bores.

Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.

Discrimination Of Cylinder Block Crankshaft Journal Bore

Mark	Cylinder block crankshaft journal bore inner diameter
A	52.000 ~ 52.006mm (2.0472 ~ 2.0475in)
B	52.006 ~ 52.012mm (2.0475 ~ 2.0477in)
C	52.012 ~ 52.018mm (2.0477 ~ 2.0479in)

Crankshaft Main Journal Mark Location

Discrimination Of Crankshaft Main Journal

Mark	Crankshaft main journal outer diameter
1	47.960 ~ 47.954mm (1.8882 ~ 1.8879in)
2	47.954 ~ 47.948mm (1.8879 ~ 1.8877in)
3	47.948 ~ 47.942mm (1.8877 ~ 1.8875in)

Crankshaft Main Bearing Color Location

Discrimination Of Crankshaft Main Bearing

Mark	Color	Crankshaft main bearing thickness
Mark	Color	No.1, 2, 3, 4, 5
A	Blue	2.026 ~ 2.029mm (0.0798 ~ 0.0799in)
B	Black	2.023 ~ 2.026mm (0.0796 ~ 0.0798in)
C	None	2.020 ~ 2.023mm (0.0795 ~ 0.0796in)
D	Green	2.017 ~ 2.020mm (0.0794 ~ 0.0795in)
E	Red	2.014 ~ 2.017mm (0.0793 ~ 0.0794in)

(8)

Select the bearing by using selection table.

Crankshaft Main Bearing Selection Table

		Cylinder block crankshaft journal bore mark
		A	B	C
Crank shaft main journal mark	1	E (Red)	D (Green)	C (None)
	2	D (Green)	C (None)	B (Black)
	3	C (None)	B (Black)	A (Blue)

Check the crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

End play

Standard: 0.05 ~ 0.25mm (0.0020 ~ 0.0098in)

Limit : 0.30mm (0.0118in)

If the end play is greater than maximum, replace the center bearing.

Cylinder Block

1.	Remove the gasket material. Using a gasket scraper, remove all the 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.

Inspect the top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

Flatness of cylinder block gasket surface

Standard :

Less than 0.05mm (0.0020in) for total area

Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in) X 100mm (3.9370in)

4.	Inspect the cylinder bore. Visually check the cylinder for vertical scratchs. If deep scratchs are present, replace the cylinder block.

Inspect the cylinder bore diameter.

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :

77.00 ~ 77.03mm (3.0315 ~ 3.0327in)

Check the cylinder bore size code on the cylinder block side surface.

Discrimination Of Cylinder Bore Size

Mark	Cylinder bore inner diameter
A	77.00 ~ 77.01mm (3.0315 ~ 3.0319in)
B	77.01 ~ 77.02mm (3.0319 ~ 3.0323in)
C	77.02 ~ 77.03mm (3.0323 ~ 3.0327in)

Check the piston size mark (A) on the piston top face.

A : Grade

S : ISG type

G : Gasoline engine

6 : 1.6L

Discrimination Of Piston Outer Diameter

Mark	Piston outer diameter
A	76.97 ~ 76.98mm (3.0303 ~ 3.0307in)
B	76.98 ~ 76.99mm (3.0307 ~ 3.0311in)
C	76.99 ~ 77.00mm (3.0311 ~ 3.0315in)

Select the piston related to cylinder bore class.

Piston -to-cylinder clearance :

0.02 ~ 0.04mm (0.0008 ~ 0.0016in)

Piston And Piston Rings

Clean the piston.

(1)	Using a gasket scraper, remove the carbon from the piston top.

(2)	Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3)

Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

The standard measurement of the piston outside diameter is taken 12mm(0.4724in) from bottom land of the piston.

Standard diameter :

76.97 ~ 77.00mm (3.0303 ~ 3.0315in)

Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.

Piston-to-cylinder clearance :

0.02 ~ 0.04mm (0.0008 ~ 0.0016in)

Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of ring groove.

Piston ring side clearance

No.1 ring : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in)

No.2 ring : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in)

Oil ring : 0.02 ~ 0.06mm (0.0008 ~ 0.0024in)

Limit

No.1 ring : 0.1mm (0.0039in)

No.2 ring : 0.1mm ( 0.0039in)

Oil ring : 0.2mm ( 0.0079in)

If the clearance is greater than maximum, replace the piston.

Inspect the piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a 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 is over the service limit, the cylinder block must be rebored.

Piston ring end gap

Standard

No.1 ring : 0.14 ~ 0.28mm (0.0079 ~ 0.0138in)

No.2 ring : 0.30 ~ 0.45mm (0.0118 ~ 0.0177in)

Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)

Limit

No.1 ring : 0.3mm(0.0118in)

No.2 ring : 0.5mm(0.0197in)

Oil ring : 0.8mm(0.0315in)