Complete removal and installation of the crankshaft, requiring engine removal from vehicle, disassembly of rotating assembly, and precision reassembly with new bearings and seals.

Warnings

Tools required

Parts

• Complete main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Complete connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Cylinder head gasket × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 8 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Crankshaft pulley bolt (TTY) × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Timing chain (if replacement needed) × 1 — Use OEM specification
• RTV silicone gasket maker (black) × 1 — Genuine Kia or equivalent

Fluids

• Kia Genuine 5W-20 Engine Oil — 4.5 qt
• Hyundai/Kia Long Life Coolant (Green) — 7.5 qt

Preparation

1. Ensure workspace has adequate overhead clearance for engine hoist (minimum 10 feet ceiling height)
2. Disconnect negative battery cable and wait 10 minutes for airbag system discharge
3. Drain engine oil completely and remove oil filter
4. Drain cooling system into appropriate container
5. Remove engine cover and air intake system
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
7. Label and photograph all electrical connectors, vacuum lines, and hose routing before disconnection
8. Support vehicle on jack stands at manufacturer-specified lift points
9. Remove both front wheels and splash shields
10. Clean work area thoroughly and have clean workspace prepared for engine disassembly

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all electrical connectors, coolant hoses, fuel lines, and vacuum lines from engine. Remove accessory drive belt. Disconnect exhaust system at manifold. Support transmission with transmission jack and remove transmission-to-engine bolts. Remove engine mount bolts. Attach engine hoist with load leveler to factory lifting points. Carefully lift engine while checking for any remaining connections. Once clear, transfer engine to engine stand and secure.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
2. 2

   Remove cylinder head and timing components
   With engine on stand, remove valve cover. Set engine to TDC cylinder #1 and mark timing chain to camshaft sprockets. Remove timing chain tensioner, then timing chain guides. Remove timing chain and camshaft sprockets. Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Lift cylinder head off block. Remove intake and exhaust manifolds if still attached. Remove timing cover bolts (both 8mm and 10mm sizes) and carefully remove timing cover.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)

   Cylinder Head Bolts65 Nm (48 lb-ft)

   Cover Bolts15 Nm (11 lb-ft)
3. 3

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse sequence and carefully separate oil pan from block using plastic scraper to avoid damaging sealing surfaces. Remove oil pump pickup tube bolts. Remove oil pump mounting bolts and extract oil pump assembly. Inspect oil pump for wear; replace if installing new crankshaft or if wear is evident.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
4. 4

   Remove crankshaft pulley and front seal housing
   Use impact wrench to remove crankshaft pulley bolt (180 Nm installed torque). Use harmonic balancer puller to remove crankshaft pulley from crankshaft snout. Remove front main seal housing bolts and carefully pry housing off crankshaft. Remove and discard front crankshaft seal.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Front Main Seal Housing12 Nm (9 lb-ft)
5. 5

   Remove flywheel and rear seal housing
   Use flywheel holder tool to prevent crankshaft rotation. Remove flywheel bolts in star pattern (loosening gradually). Remove flywheel from crankshaft. Remove rear main seal housing bolts and carefully remove housing. Remove and discard rear crankshaft seal. Note: If vehicle has automatic transmission, component will be flexplate instead of flywheel.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
6. 6

   Remove pistons and connecting rods
   Rotate crankshaft to position connecting rods at bottom dead center for easy access. Mark each rod cap and rod with corresponding cylinder number and orientation (caps must be reinstalled in exact same position). Remove connecting rod bolts. Carefully push piston and rod assemblies up and out through top of cylinder bores. Keep rod caps with their respective rods. Store piston assemblies in order.
   ⚠Rod caps and rods are machined as matched pairs. Installing caps backwards or on wrong rod will cause immediate bearing failure.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
7. 7

   Remove main bearing caps and crankshaft
   Verify main bearing caps are numbered 1-5 from front to back. Note directional arrows on caps (they point toward front of engine). Remove main bearing cap bolts in sequence from outside caps toward center (5, 1, 4, 2, then 3). Carefully lift main bearing caps straight up using cap screws or puller. With assistance, carefully lift crankshaft straight up out of engine block. Place crankshaft on protected surface. Remove main bearing shells from caps and block, keeping upper and lower bearings with their respective journals.
   ⚠️Crankshaft weighs 40-50 lbs. Use proper lifting technique and get assistance to avoid injury or dropping crankshaft.
   ⚠Main caps must be removed straight up without tilting to avoid damage to cap registers in block.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
8. 8

   Inspect and measure crankshaft and block
   Clean crankshaft thoroughly with solvent and compressed air, ensuring all oil passages are clear. Measure all main and rod journals with micrometer in multiple positions to check for taper and out-of-round condition. Standard journal diameter: main journals 2.2434-2.2442 inches, rod journals 1.8898-1.8905 inches. Maximum taper/out-of-round: 0.0004 inches. Measure block main bearing bores with dial bore gauge. Inspect block deck surface for warpage. If crankshaft journals are worn beyond specification, crankshaft must be machined and undersize bearings used, or crankshaft replaced.
   ℹ️If crankshaft requires machining, bearing clearances must be recalculated for undersize bearings (0.25mm or 0.50mm undersize typically available).
9. 9

   Install new main bearings and crankshaft
   Clean all bearing surfaces in block and caps with lint-free cloth and solvent. Install new upper main bearing shells into block, ensuring tang engages slot in bearing saddle. Lubricate bearings generously with clean engine oil. Carefully lower crankshaft into block with assistance. Install lower bearing shells into main caps. Lubricate lower bearings with clean engine oil. Install main caps in correct order and orientation (arrows toward front, numbered 1-5 front to rear). Install NEW main cap bolts finger tight. Verify crankshaft rotates freely before proceeding.
   ⚠Bearings must be installed dry in caps/block (no oil on back of bearing shell). Only bearing surface gets lubricated.
10. 10

    Torque main bearing caps and verify clearances
    Before final torque, remove caps and install Plastigage on each journal. Reinstall caps and torque to specification to check clearances. Remove caps and measure Plastigage width. Target clearance: 0.0011-0.0018 inches (0.028-0.046mm). If clearances correct, clean off Plastigage, re-oil bearings, and install caps. Tighten main cap bolts in sequence (center cap #3 first, then #2, #4, #1, #5) to 75 Nm, then additional 90 degrees angle in same sequence. Verify crankshaft rotates smoothly with no binding.
    ⚠Excessive bearing clearance causes low oil pressure and bearing failure. Insufficient clearance causes binding and seizure. Clearances MUST be within specification.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
11. 11

    Install pistons and connecting rods
    Install new connecting rod bearings in rods and caps. Lubricate bearings with clean engine oil. Stagger piston ring end gaps 120 degrees apart. Lubricate piston rings and cylinder walls with clean engine oil. Use ring compressor to compress rings. Install piston/rod assemblies into correct cylinders with mark on piston top facing front of engine. Guide rod carefully onto crankshaft journal. Install rod cap in correct orientation with NEW rod bolts. Tighten rod bolts to 45 Nm plus 90 degrees angle. Verify crankshaft still rotates freely after each rod installation. Repeat for all four cylinders.
    ⚠Do not force piston into bore. If excessive force required, rings are not properly compressed or ring compressor has slipped.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install seal housings and oil pump
    Install new front crankshaft seal into front seal housing using seal driver. Apply thin bead of RTV silicone to seal housing mating surface. Install housing onto crankshaft and torque bolts to 12 Nm in crisscross pattern. Install new rear crankshaft seal into rear seal housing. Apply RTV to rear seal housing mating surface. Install rear housing and torque bolts to 12 Nm. Install oil pump with new gasket. Torque oil pump bolts to 12 Nm. Install oil pump pickup tube with new O-ring and torque to 12 Nm.
    Torque spec

    Front Main Seal Housing12 Nm (9 lb-ft)

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
13. 13

    Install oil pan and timing components
    Apply thin bead of RTV silicone to oil pan mating surface (4-5mm bead). Install oil pan and torque bolts in sequence from center outward to 12 Nm. Allow RTV to cure 30 minutes before filling with oil. Install timing cover with new gasket. Torque 8mm timing cover bolts to 25 Nm and 10mm bolts to 45 Nm in proper sequence. Install camshaft sprockets and timing chain according to timing marks. Install chain guides and torque to 12 Nm. Compress timing chain tensioner and install pin, install tensioner and torque to 25 Nm, then release pin.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Cover Bolts15 Nm (11 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
14. 14

    Install cylinder head and flywheel
    Clean cylinder head and block mating surfaces thoroughly. Install new cylinder head gasket (do not use sealant on MLS gasket). Carefully position cylinder head onto block. Install NEW cylinder head bolts and tighten in sequence from center outward to 65 Nm, then additional 90 degrees, then final 45 degrees. Install flywheel (or flexplate for automatic) with NEW bolts. Torque flywheel bolts in star pattern to 95 Nm plus 60 degrees (or flexplate to 85 Nm).
    ⚠Cylinder head bolt tightening sequence is critical. Start from center and work outward in specified pattern to prevent head warpage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
15. 15

    Complete assembly and reinstall engine
    Install crankshaft pulley onto crankshaft snout. Install NEW crankshaft pulley bolt and torque to 180 Nm (use impact wrench or hold crankshaft). Prime oil pump using priming tool through oil filter mounting location until oil pressure builds. Install all remaining external components (valve cover, manifolds, accessories). Reinstall engine into vehicle and connect to transmission. Torque transmission-to-engine bolts to 55 Nm. Install engine mounts and torque mounting bolts to 45 Nm. Reconnect all electrical connectors, hoses, and lines. Fill with 4.5 quarts Kia Genuine 5W-20 oil and new oil filter. Fill cooling system with 7.5 quarts Hyundai/Kia coolant. Double-check all connections before starting.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts26 Nm (19 lb-ft)

Reassembly

1. Ensure all torque-to-yield (TTY) bolts have been replaced with new bolts - never reuse TTY fasteners
2. Verify timing marks are correctly aligned before buttoning up timing cover
3. All RTV silicone applications should be 4-5mm bead and components assembled within 10 minutes of application
4. Do not start engine until oil pump has been primed and proper oil pressure confirmed
5. Initial startup should be monitored carefully for oil pressure (should rise within 5 seconds), unusual noises, and leaks

Verification

• Before starting engine, manually rotate crankshaft two complete revolutions to verify no binding or interference
• Check for proper oil pressure within 5 seconds of startup (should be 15+ psi at idle when warm)
• Listen for abnormal noises during initial startup - any knocking, rattling, or grinding requires immediate shutdown and inspection
• Verify no oil leaks from pan, timing cover, or seal housings after 10 minutes of running
• Check coolant level after engine reaches operating temperature and burp cooling system
• Monitor oil pressure gauge during test drive - should maintain 25+ psi at highway speed
• Retorque cylinder head bolts after 500 miles if manufacturer specifies (check service manual)
• Perform compression test and leak-down test to verify proper ring sealing and valve sealing
• Change engine oil and filter after first 500 miles to remove any assembly residue or break-in debris

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