Kia Forte: Piston and Connecting Rod Inspection
Connecting Rod
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1. |
Check the connecting rod side clearance.
Using a feeler gauge, measure the end play while moving the connecting
rod back and forth.
| A. |
If out-of-tolerance, install a new connecting rod.
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| B. |
If still out-of-tolerance, replace the crankshaft.
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Side clearance
Standard: 0.10~ 0.25 mm (0.0039 ~ 0.0098 in.)
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2. |
Check the connecting road bearing oil clearance.
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(1) |
Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
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(2) |
Remove 2 connecting rod cap bolts.
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(3) |
Remove the connecting rod cap and lower bearing.
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(4) |
Clean the crank pin and bearing.
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(5) |
Place a plastigage across the crankshaft pin journal.
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(6) |
Reinstall the lower bearing and cap, and torque the bolts.
Tightening torque
1st step:
17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9
lb-ft)
2nd step: 88 ~ 92°
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Do not turn the crankshaft.
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• |
Do not turn the crankshaft.
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• |
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.
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(7) |
Remove the connecting rod cap and lower bearing.
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(8) |
Measure the width of the plastigage at its widest point.
Oil clearance:
0.028 ~ 0.046 mm (0.00110 ~ 0.00181 in.)
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(9) |
If the measurement from the plastigage is too wide or
too narrow, remove the upper and lower bearing and then install
new bearings with the same color mark. Recheck the oil clearance.
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Do not file, shim, of scrape the bearings or the
caps to adjust clearance.
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(10) |
If the plastigage shows the clearance is still incorrect,
try the next larger or smaller bearing. Recheck the oil clearance.
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If the proper clearance cannot be obtained by
using the appropriate larger or smaller bearings, replace
the crankshaft and repeat the check procedure.
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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.
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Connecting Rod Identification Mark
Connecting Rod Specifications
Class
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Mark
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Inside Diameter
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0
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A
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48.000 ~ 48.006 mm
(1.88976 ~ 1.89000 in.)
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1
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B
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48.006 ~ 48.012 mm
(1.89000 ~ 1.89023 in.)
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2
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C
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48.012 ~ 48.018 mm
(1.89023 ~ 1.89047 in.)
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Crankshaft Pin Identification Mark
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Conform to read stamping order as shown arrow
direction from #1.
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Crankshaft Specifications
Class
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Mark
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Outside Diameter Of Pin
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I
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1
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44.966 ~ 44.972 mm
(1.77031 ~ 1.77055 in.)
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II
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2
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44.960 ~ 44.966 mm
(1.77008 ~ 1.77031 in.)
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III
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3
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44.954 ~ 44.960 mm
(1.76984 ~ 1.77008 in.)
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Connecting Rod Bearing Identification Mark
Connecting Rod Bearing Specifications
Class
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Mark
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Thickness Of Bearing
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A
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Blue
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1.509 ~ 1.512 mm
(0.05941 ~ 0.05953 in.)
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B
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Black
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1.506 ~ 1.509 mm
(0.05929 ~ 0.05941 in.)
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C
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None
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1.503 ~ 1.506 mm
(0.05917 ~ 0.05929 in.)
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D
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Green
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1.500 ~ 1.503 mm
(0.05906 ~ 0.05917 in.)
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E
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Yellow
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1.497 ~ 1.500 mm
(0.05894 ~ 0.05906 in.)
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(11) |
Select a connecting rod bearing using selection chart.
Selection Chart For Connecting Rod Bearings
Assembling Classification Of Bearing
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Connecting Rod Identification Mark
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0 (A)
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1 (B)
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2(C)
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Crankshaft Identification Mark
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I (1)
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E
(Yellow)
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D (Green)
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C (None)
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II (2)
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D (Green)
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C (None)
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B (Black)
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III (3)
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C (None)
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B (Black)
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A (Blue)
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3. |
Check the connecting rods.
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(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.
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(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.
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(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:
0.05 mm (0.0020 in.) or less for 100 mm (3.94
in.)
Allowable twist of connecting
rod:
0.10 mm (0.0039 in.) or less for 100 mm (3.94
in.)
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When the connecting rods are installed without
bearings, there should be no difference on side surface.
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Piston
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1. |
Clean piston.
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(1) |
Using a gasket scraper, remove the carbon from the piston
top.
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(2) |
Using a groove cleaning tool or broken ring, clean the
piston ring grooves.
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(3) |
Using solvent and a brush, thoroughly clean the piston.
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2. |
Check the piston-to-cylinder clearance by calculating the difference
between the cylinder bore inner diameter and the piston outer diameter.
Piston-to-cylinder clearance:
0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in.)
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(1) |
Using a cylinder bore gauge, measure the cylinder bore
diameter at position in the thrust and axial direction.
Cylinder bore diameter:
81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)
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Measure position points (from the top of the cylinder
block):
30 mm (1.1811 in.) / 60 mm (2.3622 in.) / 90 mm
(3.5433 in.)
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(2) |
Measure the piston outside diameter at 35 mm (1.3780 in)
from top land of the piston.
Piston outside diameter:
80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)
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(1) |
Check the cylinder bore size code on the cylinder
block side surface.
Cylinder Bore Inner Diameter
Size Code
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Cylinder Bore Inner Diameter
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A
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81.00 ~ 81.01 mm (3.1890 ~ 3.1894 in.)
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B
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81.01 ~ 81.02 mm (3.1894 ~ 3.1898 in.)
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C
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81.02 ~ 81.03 mm (3.1898 ~ 3.1902 in.)
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(2) |
Check the piston size mark on the piston top face.
Piston Outer Diameter
Size Code
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Piston Outer Diameter
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A
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80.97 ~ 80.98 mm (3.1878 ~ 3.1882 in.)
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B
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80.98 ~ 80.99 mm (3.1882 ~ 3.1886 in.)
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C
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80.99 ~ 81.00 mm (3.1886 ~ 3.1890 in.)
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Piston Rings
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1. |
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston
ring and the wall of ring groove.
If the clearance is greater than maximum, replace the piston.
Piston ring side clearance
[Standard]
No.1 ring:
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
No.2 ring:
0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring:
0.060 ~ 0.135 mm (0.00236 ~ 0.00531 in.)
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If the clearance is greater than maximum, replace the piston.
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2. |
Inspect 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.
Piston ring end gap
[Standard]
No.1 ring: 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
No.2 ring: 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
Oil ring : 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in.)
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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 replaced.
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Piston Pins
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1. |
Measure the diameter of the piston pin.
Piston pin diameter:
19.996 ~ 20.000 mm (0.78724 ~ 0.78740 in.)
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2. |
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance:
0.004 ~ 0.013 mm (0.00016 ~ 0.00051 in.)
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3. |
Check the clearance between the piston pin outer diameter and
the connecting rod small end inner diameter.
Piston pin-to-connecting rod
clearance:
0.007 ~ 0.017 mm (0.00028 ~ 0.00067 in.)
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Engine removal is required for this procedure.
•
Use fender covers to avoid damaging painte ...
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Thoroughly clean all parts to be assembled.
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...
See also:
ESC OFF Switch Description
1.
The ESC OFF switch is for the user to turn off the ESC system.
2.
The ESC OFF lamp is on when ESC OFF switch is engaged.
...
Oil Cooler Inspection
Radiator Cap Testing
1.
Remove the radiator cap, wet its seal with engine coolant, and
then install it on a pressure tester.
2.
...
Installation
1.
Install in the reverse order of removal.
2.
After be equipped, perform bleeding air procedure in clutch release
cylinder after pouring t ...
Piston and Connecting Rod Disassembly
Piston and Connecting Rod Reassembly