Kia Carens. Manual — part 29

Do not rotate crankshaft with Plastigage® on crankshaft journals.

21. Remove main bearing cap and check bearing clearance.

The widest point of Plastigage® is the smallest clearance, and the narrowest point of Plastigage is the largest
clearance.

22. If oil clearance exceeds specification grind and polish crankshaft and use undersized main bearings.

Oil clearance : 0.00095~0.00165in (0.024~0.042mm)

23. Lift crankshaft out of cylinder block and carefully remove Plastigage® from main bearings and crankshaft journals.

24. Apply a light coat of engine oil on main bearing and install crankshaft by gently lowering it onto bearing.

25. Apply a light coat of oil on crankshaft main bearing journals and on main bearing on marin bearing cap.

26. Install main bearing caps along with lower main bearings according to cap number and ←mark.

27. Tighten main bearing cap bolts according to the following proedure :

A. Tighten bolts in order shown.

Tightening torque : 28.9lb·ft (39.2N·m, 4kg-m)

B. Loosen bolts in reverse or order shown.

C. Retighten bolts in order shown

Tightening torque : 14.5lb·ft (19.6N·m, 2kg-m)

D. Mark bolts for rotational reference.

E. Ratate bolt 90° (1/4turn) in order shown.

F. Rotate bolts another 60° (1/6 turn) in order shown.

28. Rotate crankshaft to ensure it does not bind.

29. Place a dial indicator against front of cranksjaft and zero gauge.

30. Using a prying tool move crankshaft forward and zero dial indicator.

31. Move the crankshaft toward the rear of block with prying tool and check the amount of movement on dial indicator.

End play : 0.0032~0.0111in (0.080~0.282mm)

32. If end play exceeds specification grind crankshaft and install oversized thrust bearings or replace crankshaft and

thrust bearing.
Thrust bearing width

Ring

Specification

Standard

0.0985~0.1003in (2.500~2.550mm)

Standard + 0.010in (0.25mm)

0.1034~0.1053in ()2.625~2.675mm)

Standard + 0.020in (0.50mm)

0.1083~0.1102in (2.750~2.800mm)

Standard + 0.030in (0.75mm)

0.1132~0.1151in (2.875~2.925mm)

33. Install a bearing into connecting rod.

34. Place rubber sleeves (Rubber fuel line work well) on connecting rod bolts to protect crankshaft from damage.

35. Check piston rings for correct end gap stagger.

36. Place piston (Cylinder number one) with "F" mark facing front of engine block, then slip piston and connecting rod

assembly into a piston ring compressor.

37. Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point (bottlm dead center).

38. Lower piston and connecting rod assembly until piston ring compressor makes contact with deck surface of engine

block.

39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes

contact with crankshaft.

Follow thos procedure for remaining piston and connecting rod assembles.

40. Install a connecting rod bearing in each connecting rod cap.

41. Place a piece of Plastigage® on crank pin journals.

42. Install connecting rod caps aligning marks made previous to disassembly and torque to specification.

Tightening torque : 34.7~36.9lb·ft (47~50N·m, 4.8~5.1kg-m)

When installing the connecting rods, match marks made on the connecting rod cap to reference mark made on
cylinder block to prevent oil starvation to the connecting rod bearings.

43. Loosen and remove connecting rod caps.

44. Check the connecting rod bearing clearance.

Oil clearance : 0.0008~0.0019in (0.020~0.05mm)
Maximu : 0.004in (0.10mm)

45. If oil clearance exceeds maximum oil clearance specification grind the crankshaft and use undersized connecting rod

bearings.

46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod bearing in connecting rod cap.

47. Install connecting rod cap and torque to specification.

Tightening torque : 34.7-36.9lb·ft (47~50N·m, 4.8~5.1kg-m)

48. Insert a thickness gauge between connecting rod and crankshaft and check connecting rod and crankshaft check

connecting rod side clearance.

Do not measure between connecting rod cap and crankshaft.

Side clearance : 0.0044~0.0103in (0.110~0.262mm)
Maximum : 0.012in (0.30mm)

49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap.

50. Apply a light coat of clean engine oil to rear oil real.

51. Install rear oil seal into rear cover by hand.

52. Press oil seal into rear cover.

Oil seal must be pressed in until it is nearly flush surface of rear cover.

Protrusion : 0~0.02in (0~0.5mm)

53. Apply a coat of slicone sealer to rear cover

Thickness : ø0.08in (2mm)

54. Install the rear cover.

Tightening torque : 5.8~8.0lb·ft (7.8~10.8N·m, 0.8~1.1kg-m)

55. Remove any sealant that protrudes fron rear cover onto oil pan mounting surface.

56. Apply clean engine oil to new front oil seal and oil pump body.

57. Install front oil seal by hand.