Kia Optima Manuals

Kia Sportage: Cylinder Block: Repair procedures - Cylinder Block - Engine Mechanical System - Kia Sportage SL Service & Repair ManualKia Sportage: Cylinder Block: Repair procedures

Third generation SL (2010–2016) / Kia Sportage SL Service & Repair Manual / Engine Mechanical System / Cylinder Block / Cylinder Block: Repair procedures

Disassembly
   
•
Use fender covers to avoid damaging painted surfaces.
•
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
   
•
Mark all wiring and hoses to avoid misconnection.
•
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
•
Engine removal is required for this procedure.
   
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don’t do any repair work right after engine stops.
1.
Remove the engine assembly from the vehicle. (Refer to Engine and transaxle assembly in this group)
2.
Install the engine to an engine stand for disassembly.
3.
Remove the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)
4.
Remove the timing chain. (Refer to Timing system in this group)
5.
Remove the cylinder head assembly. (Refer to Cylinder head in this group)
6.
Remove the drive plate (A) and the adapter plate (B).

7.
Remove the balance shaft & oil pump assembly. (Refer to Lubrication system in this group)
8.
Remove the A/C compressor. (Refer to HA group)
9.
Remove the alternator. (Refer to EE group)
10.
Remove the water pump assembly. (Refer to Cooling system in this group)
11.
Remove the tensioner assembly integrated bracket (A).

12.
Remove the oil level gauge tube (A).

13.
Remove the knock sensor (A).

14.
Remove the oil pressure sensor (A).

15.
Remove the cover (B) and then CKPS (Crankshaft position sensor) (A).

16.
Remove the ladder frame (A).

17.
Check the connecting rod end play.
18.
Remove the connecting rod caps and check oil clearance.
19.
Remove piston and connecting rod assemblies.
(1)
Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2)
Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
   
•
Keep the bearings, connecting rod and cap together.
•
Arrange the piston and connecting rod assemblies in the correct order.
20.
Remove crankshaft bearing cap and check oil clearance.
21.
Check the crankshaft end play.
22.
Lift the crankshaft (A) out of the engine, being careful not to damage journals.

   
Arrange the main bearings and thrust bearings in the correct order.
23.
Remove the oil jet (A).

24.
Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
25.
Remove piston rings.
(1)
Using a piston ring expander, remove the 2 compression rings.
(2)
Remove oil ring.
   
Arrange the piston rings in the correct order only.
26.
Disconnect connecting rod from piston.
Remove the snap ring at both ends of piston pin. And push the piston pin to seperate and connecting rod
Inspection
Connecting Rod
1.
Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.
End play :
Standard : 0.10~ 0.25mm (0.0039 ~ 0.0098in.)
Limit : 0.35mm (0.0138in.)

•
If out-of-tolerance, install a new connecting rod.
•
If still out-of-tolerance, replace the crankshaft.
2.
Check the connecting road bearing oil clearance.
(1)
Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2)
Remove 2 connecting rod cap bolts.
(3)
Remove the connecting rod cap and bearing half.
(4)
Clean the crank pin and bearing.
(5)
Place plastigage across the crank pin.
(6)
Reinstall the bearing half and cap, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
   
Do not turn the crankshaft.
(7)
Remove 2 bolts, connecting rod cap and bearing half.
(8)
Measure the plastigage at its widest point.
Standard oil clearance
0.031 ~ 0.045mm (0.00122 ~ 0.00177in.)

(9)
If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(10)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
   
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
   
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.
Connecting Rod Identification Mark

Connecting Rod Specifications
Class
Mark
Inside Diameter
a
A
51.000 ~ 51.006mm
(2.00787 ~ 2.00811in.)
b
B
51.006 ~ 51.012mm
(2.00811 ~ 2.00834in.)
c
C
51.012 ~ 51.018mm
(2.00834 ~ 2.00858in.)

Crankshaft Pin Identification Mark

   
Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class
Mark
Outside Diameter Of Pin
I
1
47.966 ~ 47.972mm
(1.88842 ~ 1.88866in.)
II
2
47.960 ~ 47.966mm
(1.88819 ~ 1.88842in.)
III
3
47.954 ~ 47.960mm
(1.88795 ~ 1.88819in.)

Connecting Rod Bearing Identification Mark

Connecting Rod Bearing Specifications
Class
Mark
Thickness Of Bearing
AA
Blue
1.515 ~ 1.518mm
(0.05965 ~ 0.05976in.)
A
Black
1.512 ~ 1.515mm
(0.05953 ~ 0.05965in.)
B
None
1.509 ~ 1.512mm
(0.05941 ~ 0.05953in.)
C
Green
1.506 ~ 1.509mm
(0.05929 ~ 0.05941in.)
D
Yellow
1.503 ~ 1.506mm
(0.05917 ~ 0.05929in.)

Selection Chart For Connecting Rod Bearings
Crankshaft Indentification Mark
Connecting Rod Identification Mark
Assembing Classification Of Bearing
I (1)
a (A)
D (Yellow)
b (B)
C (Green)
c (C)
B (None)
II (2)
a (A)
C (Green)
b (B)
B (None)
c (C)
A (Black)
III (3)
a (A)
B (None)
b (B)
A (Black)
c (C)
AA (Blue)

3.
Inspect the connecting rods.
(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.
(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.
(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 :
0.05mm (0.0020 in.) or less for 100mm (3.94 in.)
Allowable twist of connecting rod :
0.10mm (0.0039 in.) or less for 100mm (3.94 in.)
Crankshaft
1.
Check the crankshaft bearing oil clearance.
(1)
To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
(2)
Clean each main journal and bearing half with a clean shop tower.
(3)
Place one strip of plastigage across each main journal.
(4)
Reinstall the bearings and caps, then torque the bolts.
Tightening torque
14.7N.m (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125°
   
Do not turn the crankshaft.
(5)
Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.020 ~ 0.038mm (0.00079 ~ 0.00150in.)

(6)
If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
(7)
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
   
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
   
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.
Crankshaft Bore Identification Mark

Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.
Cylinder Block Specifications
Calss
Mark
Inside Diameter
a
A
56.000 ~ 56.006mm
(2.20472 ~ 2.20496in.)
b
B
56.006 ~ 56.012mm
(2.20496 ~ 2.20519in.)
c
C
56.012 ~ 56.018mm
(2.20519 ~ 2.20543in.)

Crankshaft Journal Identification Mark

   
Conform to read stamping order as shown arrow direction from #1.
Crankshaft Specifications
Class
Mark
Outside Diameter Of Journal
I
1
51.954 ~ 51.960mm
(2.04543 ~ 2.04567in.)
II
2
51.948 ~ 51.954mm
(2.04519 ~ 2.04543in.)
III
3
51.942 ~ 51.948mm
(2.04496 ~ 2.04519in.)

Crankshaft Bearing Identification Mark

Crankshaft Bearing Specifications
Class
Mark
Thickness Of Bearing
AA
Blue
2.026 ~ 2.029mm
(0.07976 ~ 0.07988in.)
A
Black
2.023 ~ 2.026mm
(0.07965 ~ 0.07976in.)
B
None
2.020 ~ 2.023mm
(0.07953 ~ 0.07965in.)
C
Green
2.017 ~ 2.020mm
(0.07941 ~ 0.7953in.)
D
Yellow
2.014 ~ 2.017mm
(0.07929 ~ 0.07941in.)

Selection Chart For Crankshaft Bearings
Crankshaft Identification Mark
Crankshaft Bore Identification Mark
Assembling Classification Of Bearing
I (1)
a (A)
D (Yellow)
b (B)
C (Green)
c (C)
B (None)
II (2)
a (A)
C (Green)
b (B)
B (None)
c (C)
A (Black)
III (3)
a (A)
B (None)
b (B)
A (Black)
c (C)
AA (Blue)

2.
Check crankshaft end play.
Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.
End play
Standard : 0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
Limit : 0.30mm (0.0118in.)

If the end play is greater than maximum, replace the thrust bearings as a set.
Thrust bearing thickness
1.925 ~ 1.965mm (0.07579 ~ 0.07736in.)
3.
Inspect main journals and crank pins.
Using a micrometer, measure the diameter of each main journal and crank pin.
Main journal diameter :
51.942 ~ 51.960mm (2.04496 ~ 2.04567in.)
Crank pin diameter :
47.954 ~ 47.972mm (1.88795 ~ 1.88866in.)

Cylinder Block
1.
Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2.
Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
3.
Inspect 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
Standard : Less than 0.05mm (0.0019in.) for all
Less than 0.02 (0.0007in.) for 100mm (3.9370in.) x 100mm (3.9370in.)

4.
Inspect cylinder bore diameter.
Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.
5.
Inspect cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.
Standard diameter
86.00 ~ 86.03mm (3.3858 ~ 3.3870in.)

   
Measurement position points (from the bottom of the cylinder block)
: 110.7mm(4.3582in.)/160mm(6.2992in.)/210mm(8.2677in.)
6.
Check the cylinder bore size code on the cylinder block.

Cylinder Bore Inner Diameter
Size Code
Cylinder Bore Inner Diameter
A
86.00 ~ 86.01mm (3.3858~ 3.3862in.)
B
86.01 ~ 86.02mm (3.3862~ 3.3866in.)
C
86.02 ~ 86.03mm (3.3866~ 3.3870in.)

7.
Check the piston size code on the piston top face.

   
Stamp the grade mark of basic diameter with rubber stamp.
Piston Outer Diameter
Size Code
Piston Outer Diameter
A
85.970 ~ 85.980mm (3.3846 ~ 3.3850 in)
B
85.980 ~ 85.990mm (3.3850 ~ 3.3854in.)
C
85.990 ~ 86.000mm (3.3854 ~ 3.3858in.)

8.
Select the piston related to cylinder bore class.
Clearance : 0.020 ~ 0.040mm (0.00079 ~ 0.00157in.)
Piston And Rings
1.
Clean piston
(1)
Using a gasket scraper, remove the carbon from the piston top.
(2)
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
(3)
Using solvent and a brush, thoroughly clean the piston.
   
Do not use a wire brush.
2.
The standard measurement of the piston outside diameter is taken 17mm (0.67in.) from the top land of the piston.
Standard diameter
85.970 ~ 86.000mm (3.3846 ~ 3.3858in.)

3.
Calculate the difference between the cylinder bore diameter and the piston diameter.
Piston-to-cylinder clearance
0.020 ~ 0.040mm (0.00079 ~ 0.00157in.)
4.
Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.
Piston ring side clearance
Standard
No.1 : 0.050 ~ 0.080mm (0.00197 ~ 0.00315in.)
No.2 : 0.040 ~ 0.080mm (0.00157 ~ 0.00315in.)
Oil ring : 0.020 ~ 0.055mm (0.00079 ~ 0.00217in.)
Limit
No.1 : 0.100mm (0.00394in.)
No.2 : 0.100mm (0.00394in.)
Oil ring : 0.100mm (0.00394in.)

If the clearance is greater than maximum, replace the piston.
5.
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. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits, If the bore is over the service limit, the cylinder block must be replaced.
Piston ring end gap
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.37 ~ 0.52m (0.0145 ~ 0.0204in.)
Oil ring : 0.20 ~ 0.50mm (0.0079 ~ 0.0197in.)
Limit
No.1 : 0.60mm (0.0236in.)
No.2 : 0.70mm (0.0275in.)
Oil ring : 0.80mm (0.0315in.)

Piston Pins
1.
Measure the diameter of the piston pin.
Piston pin diameter
21.997 ~ 22.000mm (0.86602 ~ 0.86614in.)

2.
Measure the piston pin-to-piston clearance.
Piston pin-to-piston clearance
0.003 ~ 0.010m (0.00012 ~ 0.00039in.)
3.
Check the difference between the piston pin diameter and the connecting rod small end diameter.
Piston pin-to-connecting rod interference
0.005 ~ 0.014mm (0.00020 ~ 0.00055in.)
Reassembly
   
•
Thoroughly clean all parts to assembled.
•
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
•
Replace all gaskets, O-rings and oil seals with new parts.
1.
Assemble the piston and connecting rod.
(1)
The piston front mark and the connecting rod front mark must face the timing chain side of the engine.

(2)
Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
   
•
Take care that piston pin is not damaged during reassemble .
•
When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.
Piston pin outer diameter : 21.997 ~ 22.000mm (0.8660 ~ 0.8661in)
Piston pin hole inner diameter : 22.003mm ~ 22.007mm (0.8662 ~ 0.8664in)
Connecting rod small end inner diameter : 22.005 ~ 22.011mm (0.8663 ~ 0.8665in)
Interference : -0.014mm ~ -0.005mm (0.0006 ~ 0.0002in)
(3)
Set the snap ring in one side of piston pin hole and insert the piston pin into the piston pin hole & the small end bore of connecting rod while meeting the front mark of connecting rod & piston.
   
Be sure to keep the small end bore, pistonpin hole & piston pin from being damaged and scratched when inserting the piston pin.
   
Assembling condition
Temperature : piston side 70 to 80C , connecting rod & pin is to be normal room temperature.
(4)
After inserting the piston pin, set the snap ring of the other side.
   
Set the snap ring so that it contacts completely with the groove of the piston pin hole.
The snap ring must not be deformed from the installation tooling method.
2.
Install the piston rings.
(1)
Install the oil ring with coil spring by hand.
(2)
Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3)
Position the piston rings so that the ring ends are as shown.

3.
Install the connecting rod bearings.
(1)
Align the bearing claw with the groove of the connecting rod or connecting rod cap.
(2)
Install the bearings(A) in the connecting rod and connecting rod cap(B).

4.
Install the main bearings.
   
Upper bearings have an oil groove of oil holes; Lower bearings do not.
(1)
Align the bearing claw with the claw groove of the cylinder block, push in the 5 upper bearings(A).

(2)
Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5.
Install the thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.

6.
Install the oil jet (A).
Tightening torque
24.5 ~ 29.4Nm (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)

7.
Place the crankshaft(A) on the cylinder block.

8.
Place the main bearing caps on cylinder block.
9.
Install the main bearing cap bolts.
   
Always use new main bearing cap bolts.
   
•
The main bearing cap bolts are tightened in 3 progressive steps.
•
If any of the bearing cap bolts in broken or deformed, replace it.
(1)
Apply a light coat of engine oil on the threads and under the bearing cap bolts.
(2)
Using the SST (09221-4A000), install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Tightening torque
14.7N.m (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125°

(3)
Check that the crankshaft turns smoothly.
10.
Check crankshaft end play.
11.
Install piston and connecting rod assemblies.
   
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
(1)
Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
(2)
Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
(3)
Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
(4)
Apply engine oil to the bolt threads. Using the SST (09221-4A000), install the rod caps with bearings, and torque the bolts.
Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°
   
Always use new connecting rod cap bolts.
   
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.

12.
Apply liquid gasket to the mating surface of cylinder block and ladder frame.
   
•
When assembling ladder frame, the liquid sealant Loctite 5900H, Threebond 1217H or equivalent should be applied ladder frame.
•
The part must be assembled within 5 minutes after sealant was applied.
•
Apply sealant to the inner threads of the bolt holes.

13.
Install ladder frame(A) with 10 bolts, in several passes, in sequence shown.
Tightening torque
Step 1 : 8.8 ~ 9.8N.m (0.9 ~ 1.0kgf.m, 6.5 ~ 7.2lb-ft)
Step 2 : 17.7 ~20.6N.m (1.8 ~ 2.1kgf.m, 13.0 ~ 15.2lb-ft)
Step 3 : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

(1)
Tighten the bolts in order number as shown with the 3 steps.
(2)
Loosen the bolts as reverse tightening order.
(3)
Tighten the bolts in order number as shown with the 3 steps.

14.
Install rear oil seal.
(1)
Apply engine oil to a new oil seal lip.
(2)
Using SST(09231-H1100, 09214-3K100) (B) and a hammer, tap in the oil seal (A) until its surface is flush with the rear oil seal retainer edge.

15.
Install CKPS (Crankshaft position sensor) (A) and sensor cover (B).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

16.
Install oil pressure switch.
(1)
Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(B) or equivalent.
(2)
Install the oil pressure switch (A).
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

17.
Install knock sensor(A).
Tightening torque
18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)

18.
Install oil level gauge assembly.
(1)
Install a new O-ring on the oil level gauge.
(2)
Apply engine oil on the O-ring.
(3)
Install the oil level gauge assembly(A) with the bolt.
Tightening torque
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

19.
Install tensioner assembly integrated bracket(A).
Tightening torque
39.2 ~ 44.1N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)

20.
Install the water pump. (Refer to Cooling system in this group)
21.
Install the alternator. (Refer to EE group)
22.
Install the balance shaft & oil pump assembly. (Refer to Lubrication system in this group)
23.
Install the cylinder head assembly. (Refer to Cylinder head in this group)
24.
Install the timing chain. (Refer to Timing system in this group)
25.
Install the intake manifold and exhaust manifold.
(Refer to Intake and exhaust system in this group)
26.
Remove the engine from the engine stand.
27.
Install the drive plate (A) and the adapter plate (B).
Tightening torque :
117.7 ~ 127.5N.m (12.0 ~ 13.0kgf.m, 86.8 ~ 93.9lb-ft)

   
•
Always use new drive plate bolts.
•
Apply sealant to the screw part (10mm from the end of the bolt) when reusing the drive plate bolts.
Sealant: Three bond 2403, Loctite 200 or 204
•
Install and uniformly tighten the 7 bolts, in several passes.
28.
Install the engine assembly on the vehicle.
(Refer to Engine and transaxle assembly in this group)
Add all fluids to their normal operating levels.
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