KIA Sportazh - Kia Sportage
Controls and operation receptions
Current leaving and service
The engine
   Check компрессионного pressure, an estimation of a condition of cylinders
   Check of the engine by means of the vacuum gauge
   Belts of a drive of auxiliary units
   Petrol models
      Greasing system - the general information, check of pressure of impellent oil
      Removal and engine installation
      Removal and installation of components of drive ГРМ
      Removal and installation of the inlet pipeline and final collector
      Service of a head of cylinders and components газораспределительного the mechanism
      Dismantling and assemblage of the block of cylinders, service of components
      Removal and pallet installation картера
      Removal, installation and service of the oil pump
      Removal and installation of a flywheel/privodnogo of a disk
      Removal and installation маслораспылителей
      Replacement of epiploons of a cranked shaft
   Diesel models
Systems of cooling, heating, ventilation and air conditioning
Power supply systems, managements of the engine/decrease of toxicity of the fulfilled gases and release of the fulfilled gases
Systems of an electric equipment of the engine
Five-step manual box of a gear change
Automatic transmission
Transmissionnaja line
Brake system
Suspension bracket and steering
Body
Onboard electric equipment
Control кузовные the sizes
Schemes of electric connections




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Kia Sportage>> The engine>> Petrol models>> Dismantling and assemblage of the block of cylinders, service of components

Dismantling and assemblage of the block of cylinders, service of components

Dismantle and installation of a cranked shaft and shatunno-piston assemblages can be made without removal of the engine from the car.

Dismantling

Design of the block of cylinders (see also an illustration of the Detail of installation of a flywheel/privodnogo of a disk)

1 — the Cover of the bottom head of a rod
2 — Loose leaves шатунного the bearing
3 — the Rod with the piston
4 — the Piston finger
5 — Piston rings

6 — the Cover of the radical bearing
7 — the Cranked shaft
8 — the Directing bearing
9 — the Loose leaf of the radical bearing
10 — block Moulding
11 — the Lock ring


 PERFORMANCE ORDER

  1. Remove the engine (the Section of System of an electric equipment of the engine see).
  2. Remove a head of cylinders (see Has undressed Service of a head of cylinders and components газораспределительного the mechanism).
  3. Remove the oil pump (see Has undressed Removal, installation and service of the oil pump).
  4. Remove the pallet картера and a flywheel/privodnoj a disk (see Has undressed Removal and pallet installation картера).
  5. Remove a back epiploon with a cover (the Section Replacement of epiploons of a cranked shaft see).
  6. Turn out fixing bolts and remove covers of radical bearings with gathering with loose leaves.
  7. Turn out fixing bolts and uncover the bottom head of the first rod in gathering with the loose leaf. Rest against a head of a rod the handle of a hammer and, pushing shatunno-piston assemblage upwards, take it from the cylinder.
  8. Operating in a similar manner, take the remained assemblages.
  9. For the purpose of mess prevention at check of a condition of components at once establish on the former places of a cover шатунных and radical bearings of a cranked shaft in gathering with loose leaves and fix their fixing bolts.
  10. By means of an inertial stripper dismantle established in a back pin of a cranked shaft directing bearing (see an illustration).

Service

 PERFORMANCE ORDER

  1. Attentively study a condition of moulding of the block. Check up each cylinder on presence of cracks, задиров and other mechanical damages.
  2. Operating in the manner similar described in Section Dismantling and assemblage of the block of cylinders, service of components, estimate degree of infringement of planeness interfaced to a head of cylinders of a surface of the block (see an illustration). In case of need replace the block.

Restoration of planeness of an interfaced surface of the block by its machining is not admissible at all!

  1. Teases of mirrors cylinders can be pierced till the corresponding repair size, in a case if such processing is not represented possible, replace the block.
  1. Measure diameter of each of cylinders at three levels and in two directions that will allow to reveal such defects, as конусность and ovality. If results of measurements exceed limiting admissible values (Specifications of the Head the Engine see), cylinders should be chiseled till next repair size. In conclusion of a mirror of cylinders should be отхонингованы, - operate according to the instructions applied to special хонинговочным to sets.
  1. Special vertical drill remove the step deterioration of cylinders left top компрессионным the ring in the end of a course of pistons.
  1. Remove lock rings, take piston fingers and make dismantle of pistons from rods.
  2. Study a condition of pistons, in case of revealing of cracks, задиров and other mechanical damages prepare replacement.
  1. Measure diameter of each piston in a direction, perpendicular axes of a piston finger and on removal in 18 mm from the bottom cut of a flute under installation маслосъемного rings. By comparison of result of measurement with size of diameter of the corresponding cylinder define size landing люфта. If люфт exceeds limiting admissible value, replace the piston, having pierced the cylinder till next repair size.

Simultaneously with the piston it is necessary to replace also piston rings (on corresponding the repair size, - Specifications of the Head the Engine see).

  1. Check up piston rings on presence of signs of excessive deterioration, cracks, having chopped off and other mechanical damages. In case of need make replacement.
  2. Serially filling piston rings in the cylinder and pushing their bottom of the piston in the bottom part of the last (position НМТ of the piston), measure sizes of backlashes in locks of rings (see an illustration). Compare results of measurements to requirements of Specifications of the Head the Engine, in case of need chisel locks, or replace rings.
  3. Measure size люфта landings of rings in flutes of pistons (see an illustration), in case of need replace a ring/piston.

Measurement should be made in several points of perimetre of a flute. From this point on rings should remain "adhered" to the pistons/cylinders.

  1. At the special stand believe rods on presence of signs of a bend and twisting (see an illustration). At excess by results of measurements of limiting admissible values replace defective components.
  1. Measure diameters under landing of piston fingers in pistons. Write down results of measurements.
  1. Measure diameter of piston fingers in places from запрессовки in the piston.
  1. By subtraction of results of the first measurements from results of the second define a ljuft/tightness of landing of fingers in pistons.
  2. By measurement of corresponding diameters of piston fingers and apertures in the top heads of rods define люфты landings of fingers in rods. At excess by results of calculations of limiting admissible value make replacement of rods.
  3. Attentively study a condition of a cranked shaft. Check up its root and шатунные necks on presence задиров, traces of an overheat and other mechanical damages. Make sure of absence of infringements of passableness of oil apertures.
  4. Having laid a shaft in prisms, check up it on presence of a bend by means of measuring instrument DTI (see an illustration).
  5. Measure diameters of necks, estimate their sizes конусности and ovality. If deterioration of necks exceeds limiting admissible value, pierce them under the next repair size (do not forget to pick up the corresponding size repair loose leaves), or replace a shaft.

At all do not cut off a rounding off of necks, - the minimum admissible radius of a rounding off makes 2.6 3 mm.


The radius of roundings off of necks should make not less than 2.6 3.0 mm.
  1. Study a condition of loose leaves of bearings. In case of revealing of defects prepare the replaceable complete set. Spread out loose leaves as their installation to the engine.

Assemblage

 PERFORMANCE ORDER

  1. Before the assemblage beginning make sure of absoluteness of cleanliness of all components.
  1. Correct image arrange the piston concerning a rod.
  1. Grease with pure impellent oil of an aperture in the piston and the top head of a rod.
  2. By means of special nippers plant a lock ring in a flute in one of piston apertures, then fill in last the top head of a rod.
  1. Through approaching оправку accurately begin to knock a piston finger, having fixed the piston on a rod. Fix a finger the second lock ring.
  1. Operating in a similar manner, mount the remained shatunno-piston assemblages.
  2. Plant on pistons the picked up earlier piston rings: at first in the bottom flute of the piston preliminary oiled dilator маслосъемного rings is established, then its working sections (scrapers) are got.
Landing of the top scraper маслосъемного rings.
The scheme of installation of components маслосъемного rings.

Scrapers маслосъемного rings are identical on a design and do not demand unambiguity of landing at installation.


  1. Further, in the remained flutes refuel also plentifully greased bottom and top компрессионные rings (do not mix a ring - they differ under the section form), - track correctness of placing of rings, - they should be established by the marked letter R the party upwards.
  1. Develop the rings planted on pistons locks in the specified directions.
  1. Plant in the block of cylinders маслораспылители and tighten bolts of their fastening with demanded effort (12 18 Nanometers).
  1. Carefully wipe necks of a cranked shaft, a back of loose leaves of radical bearings and their bed in the block, completely having removed from them oil traces. Enclose loose leaves and establish a shaft.

The central radical bearing is persistent.

  1. Once again wipe radical necks of a shaft, lay along them the calibrated plastic wire from set Plastigage for definition of working backlashes in sliding bearings.

Watch, that the wire did not keep within over oil apertures of necks!


  1. Wipe backs of loose leaves of bearings and their bed in covers, then establish the last, having tracked correctness of placing and, operating strictly in a certain order, tighten bolts of their fastening with demanded effort.
  1. Release fixture, remove covers and, measuring width of the flattened out wire on a scale put on packing of set Plastigage, define sizes of backlashes in radical bearings.

During check do not turn a cranked shaft! If the result of measurement exceeds limiting admissible value, make selection of new loose leaves, in case of need pierce a shaft till the corresponding repair size and establish repair loose leaves.

  1. Having finished check, grease working surfaces of the picked up loose leaves and radical necks of a shaft with pure impellent oil, lay a shaft in the block.
  2. Establish covers of radical bearings, push a shaft forward against the stop, then return it back and tighten bolts of fastening of covers with demanded effort.
  1. Check up size axial люфта a cranked shaft and its freedom проворачивания. Compare result of measurement to requirements of Specifications of the Head the Engine, in case of need pick up the new persistent bearing.
  1. By means of approaching оправки, plant on a back pin of a shaft directing bearing (see an illustration), - do not forget to grease preliminary the bearing and a pin with impellent oil. After installation fill the bearing консистентной greasing.
  2. Accurately fill shatunno-piston assemblages in the cylinders: and a mirror of cylinders before installation it is necessary to grease walls of pistons with pure impellent oil, piston rings to press out special оправкой; pushing through of pistons in cylinders is better to make the hammer handle. Track, that pistons have been established by labels in the form of letters F forward on the engine.

At resistance occurrence it is necessary to stop immediately piston pushing through, to take assemblage and to make sure of completeness of removal of step deterioration in the top part of the cylinder!

  1. Having planted the bottom heads of rods on шатунные shaft necks, make gauging of working backlashes in шатунных bearings, - operate in the manner similar described above for radical bearings. Remember that loose leaves of bearings at check should be established on dry, track correctness of an arrangement of covers.
  2. With the help щупа лезвийного type make gauging of sizes axial люфтов rods (see an illustration). Compare results of measurements to requirements of Specifications of the Head the Engine, in case of need replace corresponding rods.
  3. Finalise шатунные covers (having oiled working surfaces of bearings), - track correctness of combination of landing labels and tighten bolts of their fastening with demanded effort.

Before a tightening also it is necessary to grease carving parts of bolts and nuts with pure impellent oil.

  1. The further installation make in an order, the return to an order of dismantle of components.