Kia Sportage: Cylinder Block / Cylinder Block Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Engine Mechanical System / Cylinder Block / Cylinder Block Repair procedures

Disassembly
  
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.
  
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
  
Mark all wiring and hoses to avoid misconnection
1.
Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - “Engine and Transaxle Assembly”)
2.
Remove the transaxle assembly from the engine assembly.
(Refer to Automatic Transaxle System - "Automatic Transaxle")
3.
Remove the drive plate.
(Refer to Cylinder Block - "Drive Plate")
4.
Install the engine to engine stand for disassembly.
5.
Remove the intake manifold.
(Refer to Intake and Exhaust System - "Intake Manifold")
6.
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "Exhaust Manifold")
7.
Remove the timing chain.
(Refer to Timing System - “Timing Chain”)
8.
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "Cylinder Head")
9.
Remove the A/C compressor.
(Refer to Heating, Ventilation Air conditioning - "Compressor")
10.
Remove the alternator.
(Refer to Engine Electrical System - "Alternator ")
11.
Remove the water temperature control assembly.
(Refer to Cooling System - "Water Temperature Control Assembly")
12.
Remove the balance shaft & oil pump.
(Refer to Lubrication System - "Balance Shaft & Oil Pump")
13.
Remove the ladder frame.

14.
Remove the piston & connecting rod assembly.
(Refer to Cylinder Block - "Piston and Connecting Rod")
15.
Remove the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
16.
Remove the knock sensor.
(Refer to Engine Control/Fuel System - "Knock Sensor")
17.
Remove the crankshaft Position Sensor (CKPS).
(Refer to Engine Control/Fuel System - "Crankshaft Position Sensor")
18.
Remove the oil pressure sensor.
(Refer to Lubrication System - "Oil Pressure Sensor")
19.
Remove the oil jet (A).

Inspection
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 contacting surface of the cylinder block and the manifolds for warpage.
Flatness of cylinder block gasket surface
Standard : Less than 0.05 mm (0.0019 in.) for all
Less than 0.02 mm (0.0007 in.) for 100 mm (3.9370 in.) x 100 mm (3.9370 in.)

4.
Inspect cylinder bore diameter.
Visually check the cylinder for vertical scratches.
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 :
88.00- 88.03 mm (3.4645 - 3.4657 in.)

  
Measure position points (from the bottom of the cylinder block)
: 110.7 mm (4.3582 in.) / 160 mm (6.2992 in.) / 210 mm (8.2677 in.)
Reassembly
1.
Install the oil jet (A).
Tightening torque :
24.5 - 29.4 N·m (2.5 - 3.0 kgf·m, 18.1 - 21.7 lb·ft)

2.
Install the oil pressure switch.
(Refer to Lubrication System - "Oil Pressure Switch")
3.
Install the crankshaft position sensor (CKPS).
(Refer to Engine Control/Fuel System - "Crankshaft Position Sensor")
4.
Install the knock sensor.
(Refer to Engine Control/Fuel System - "Knock Sensor")
5.
Install the crankshaft.
(Refer to Cylinder Block - "Crankshaft")
6.
Install the piston & connecting rod assembly.
(Refer to Cylinder Block - "Piston and Connecting Rod")
7.
Apply liquid gasket to the mating surface of cylinder block and ladder frame.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in)

  
When assembling ladder frame, the liquid sealant Loctite 5900H, Three bond 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.
8.
Install ladder frame (A) with 10 bolts, in several passes, in sequence shown.
Tightening torque
Step 1 :
8.8 - 9.8 N·m (0.9 - 1.0 kgf·m, 6.5 - 7.2 lb·ft)
Step 2 :
17.7 - 20.6 N·m (1.8 - 2.1 kgf·m, 13.0 - 15.2 lb·ft)
Step 3 :
27.5 - 31.4 N·m (2.8 - 3.2 kgf·m, 20.3 - 23.1 lb·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.

9.
Assemble the other parts in the reverse order of disassembly.
  
In case the cylinder block is replaced with a new one, select the proper crankshaft main bearing and the piston according to the crankshaft journal bore mark and the cylinder bore mark on the cylinder block.
Crankshaft main bearing selection
(Refer to Cylinder Block - "Crankshaft")
Piston selection
(Refer to Cylinder Block - "Piston and Connecting Rod")
Crankshaft Repair procedures
Disassembly    In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and in ...

Cylinder Head Assembly
...

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