Kia 231112G200 Crankshaft

The crankshaft has to be pulled out only after the engine is removed out from the car and barring other conditions like the attachment of the flywheel, crankshaft pulley, timing belt or chain, oil pan, oil pump body or the oil filter and piston/connecting rod assemblies are being removed. To do this, set the dial indicator on the face of the crankshaft as illustrated in the figure before removal of the motor. Rotate the crankshaft thereafter to the rear then draw the reading of the indicator which should ordinarily range from 0.003 to 0.010-inch to the front. In case one cannot use a dial indicator, you can use feeler gauges to measure clearance. Drain the main bearing cap bolts slowly; you should be able to undo the bolts by hand starting from about the sixth turn with the help of a271/64 soft-face hammer. Lever the crankshaft out slowly, preferably with help because of the weight. For installation, it is necessary to check and clean the engine block and crankshaft for installation. Turn the block in such a manner that the bottom is facing up, take off the main bearing caps and replace the bolts but keep the old ones with you to check the oil clearance. Scrub the bearing contact surfaces and replace the upper main bearing inserts as well as make sure that there is a correct oiling hole disposition. The status of the oil clearance should be checked using Plastigage and by comparing the width of the crushed cross-section with the scale. In case of rejecting the clearance, check the absence of contaminants and think about the utilization of other bearing dimensions if needed. Once the Plastigage gunk is washed away, it is advisable to spread some grease or assembly lube on the bearing surfaces before replacing the crankshaft. Fit in the main bearing caps and torque up the bolts following a specified pattern and re-check the crankshaft end play if any. Turn the crankshaft, checking for any binding and if any exist, rectify them before fitting a new rear main oil seal.

The crankshaft has to be removed with the engine extracted from the car, provided it is free of such parts as the flywheel, crankshaft pulley, timing belt or chain, oil pan, oil pump body, oil filter as well as piston/con-rod assemblies. Before the puller is applied, one needs to check the end play of the crankshaft by setting a dial indicator to the crankshaft and observing the distance that it moves back and forward when the crankshaft is pricked to the rear and then forward. End play is usually between 0.003 and 0.010 inches (.076 and 0.254 mm); if it is higher, check the thrust faces for wear. As we mentioned earlier, when a dial indicator in not available feeler gauges can also be used measure clearance. Leverage the cap of main bearings and undertake the following processes, you have to tighten them in a gradual manner in order to remove them, however before doing so new bolts should replace the old ones in instances where they are used. Lift off the main caps as well as the thrust bearing caps and carefully lift the crankshaft off, preferably with help since they are usually very heavy. For installation, be sure that engine block and crank main are clean and examinated. Align the block with its bot tom upwards to remove any contaminants and take out the original bearing inserts; the mating surfaces should be cleaned. New upper main bearing inserts must be pressed into the main bearing journals; check that oil hole is matched with the others before inserting the lower inserts into the main bearing caps. Care should be taken not to mar the inserts and similarly there should be no application of lubrication at this point. Before laying the crankshaft, ensure the oil holes in the crankshaft are clean. To measure main bearing oil clearance, you should apply Plastigage to each journal, place the main bearing caps as they should be without shifting the Plastigage, then, and finally, tighten the bolts in the right manner. Upon taking out the caps, measure the Wmax of the crushed Plastigage and look on the scale to check the clearance, making sure no contaminants are on it. If clearance is incorrect, measure the bearings inserts diameters, and look for tapering on the crankshaft journal. Wipe off any Plastigage deposits on the journals and insert faces and apply a layer of moly-base grease or engine assembly lube on the bearings before replacing the crankshaft. It should be noted that all mating surfaces must be kept clean and free of oil, fresh engine oil must be applied to new bolt threads and tightened to the required torque, but no less. Check the crankshaft end float again and turn the crankshaft it should rotate smoothly and if not free the crankshaft, components or any other pulley that is causing binding. Last of all, fit the new rear main oil seal as well.