Kia Forte: Cylinder Block / Cylinder Block

Kia Forte 2019-2024 (BD) Service Manual / Engine Mechanical System / Cylinder Block / Cylinder Block

Repair procedures

Disassembly

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.

•	When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.

•	To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

•	Mark all wiring and hoses to avoid misconnection.

•	Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.

1.	Remove the engine and transmission assembly from the vehicle. (Refer to Engine and Transmission Assembly - "Engine and Transmission Assembly")

2.	Remove the transaxle assembly. Manual Transaxle System: (Refer to Manual Transaxle System - "Manual Transaxle") DCT (Double Clutch Transmission) System : (Refer to DCT (Double Clutch Transmission) System - "DCT (Double Clutch Transmission)")

3.	3. Remove the flywheel. (Refer to Cylinder Block - "Flywheel")

4.	Remove the rear oil seal. (Refer to Cylinder Block Assembly - "Rear Oil Seal")

5.	Install the engine assembly to engine stand for disassembly.

6.	Remove the intake manifold. (Refer to Intake and Exhaust System - "Intake Manifold")

7.	Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")

8.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

9.	Remove the cylinder head assembly. (Refer to Cylinder Head Assembly - "Cylinder Head")

10.	Remove the oil cooler. (Refer to Lubrication System - "Oil Cooler")

11.	Remove the oil pressure switch. (Refer to Lubrication System - "Oil Pressure Switch")

12.	Remove the crankshaft position sensor. (Refer to Engine Control / Fuel System - -"Crankshaft Position Sensor (CKPS)")

13.	Remove the oil pan and the oil screen. (Refer to 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 connecting rod bearing cap oil clearance. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

17.	Remove the piston and connecting rod assemblies. (Refer to Cylinder Block Assembly - "Piston and Connecting Rod")

18.	Check the main bearing oil clearance. (Refer to Cylinder Block Assembly - "Crankshaft")

19.	Check the crankshaft end play. (Refer to Cylinder Block Assembly - "Crankshaft")

20.	Remove the crankshaft. (Refer to Cylinder Block Assembly - "Crankshaft")

21.	Remove the water inlet fitting and thermostat. (Refer to Cooling System - "Thermostat")

22.	Remove the knock sensor. (Refer to Engine Control / Fuel System - "Knock Sensor (KS)")

Inspection

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

2.	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 :

Less than 0.05 mm (0.0020 in) for total area

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

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.

Cylinder bore diameter :

77.00 - 77.03 mm (3.0315 - 3.0327 in)

Reassembly

Install in the reverse order of disassembly.

In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block.

•	Crankshaft main bearing selection (Refer to Cylinder Block Assembly - "Crankshaft")

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

Crankshaft

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