KIA Sportazh - Kia Sportage
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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
   Diesel models
      Greasing system - the general information
      Removal and engine installation
      Removal and installation of components of drive ГРМ
      Check and adjustment клапанных backlashes
      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 маслоохладителя
      Removal and flywheel installation
      Removal and installation маслораспылителей
      Replacement of epiploons of a cranked shaft
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
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Control кузовные the sizes
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Kia Sportage>> The engine>> Diesel 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

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

7 — Covers of radical bearings
8 — the Cranked shaft
9 — Loose leaves of radical bearings and persistent half rings
10 — the Directing bearing
11 — Masloraspylitel
12 — block Moulding


 PERFORMANCE ORDER

  1. Remove the engine (see Has undressed Removal and engine installation).
  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 and pallet installation картера).
  4. Remove the pallet картера and a flywheel/privodnoj a disk (Sections Dismantling and assemblage of the block of cylinders, service of components and Removal and installation маслоохладителя see).
  5. Remove a back epiploon with a cover (see Has undressed Removal and installation маслораспылителей).
  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.
  1. By means of an inertial stripper dismantle established in a back pin of a cranked shaft directing bearing.

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.
  1. Operating in the manner similar described in Section Service of a head of cylinders and components газораспределительного of the mechanism, estimate degree of infringement of planeness interfaced to a head of cylinders of a surface of the block. 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 two directions that will allow to reveal such defects, as конусность and ovality. Results write down. By subtraction from the maximum result minimum define degree of deterioration of the cylinder and if it exceeds limiting admissible value (see Specifications of the Head the Engine), 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.
  2. Remove lock rings, take piston fingers and make dismantle of pistons from rods.
  3. Study a condition of pistons, in case of revealing of cracks, задиров and other mechanical damages prepare replacement.
  4. Measure diameter of each piston in a direction, perpendicular axes of a piston finger, and on removal in 19 mm from the bottom cut of a skirt. 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.
1 — the Control 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.
  1. 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. Compare results of measurements to requirements of Specifications of the Head the Engine, in case of need chisel locks, or replace rings.
  1. Measure size люфта landings of rings in flutes of pistons, in case of need replace a ring/piston.
1 — Top компрессионное a ring
2 — the Second компрессионное and маслосъемное rings

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. At excess by results of measurements of limiting admissible values replace defective components.
  1. By measurement of corresponding diameters of piston fingers and plugs of the top heads of rods define люфты landings of fingers in plugs. At excess by results of calculations of limiting admissible value make replacement of the worn out plugs.
  2. Plug squeezing is made with the help оправки in diameter 27 27.5 mm.
  3. Before запрессовкой grease the new plug and a rod with pure impellent oil. Track correctness of combination of lubricant apertures. After запрессовки develop the plug development to rating value of internal diameter.
Запрессовывание and working out of the plug (2) top heads of a rod, - track correctness of combination of oil apertures (1).
  1. 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.
  1. Having laid a shaft in prisms, check up it on presence of a bend by means of measuring instrument DTI.
  1. 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 (see an illustration), - the minimum admissible radius of a rounding off makes 2.6 3 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. Warm up the piston to temperature 50 70 С. Grease шатунную the plug and apertures in piston inflow by pure oil, then fill in the piston one of lock rings. Get a rod in the piston and fix its piston finger and establish the second lock ring, - track correctness of an arrangement from each other an oil aperture on a rod and labels F on the piston. Operating in a similar manner, mount all shatunno-piston assemblages.
  1. Plant on pistons the picked up earlier piston rings: at first in the bottom flute of the piston the dilator маслосъемного rings is established, then its working sections are got. Further, in the remained flutes refuel bottom and top компрессионные rings (do not mix a ring - they differ under the section form), - track correctness of placing of rings.
1 — the Identification label
2 — the Piston ring
3 — Upwards
4 — Top компрессионное a ring
5 — the Second компрессионное a ring
6 — Working section маслосъемного rings

Rings should be established the marked letter Y the party upwards.

  1. Develop the rings planted on pistons locks in the specified directions.
1 — the Top ring and a spring dilator маслосъемного rings
2 — the Second компрессионное a ring
3 — Working sections маслосъемного rings
  1. 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. Plant in the block of cylinders маслораспылители and tighten bolts of their fastening with demanded effort
    (12 18 Nanometers).
  2. 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.
  3. 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.
The scheme of installation of covers of radical bearings.
Order of a tightening of fixture of covers of radical bearings.
  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 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. Enclose in assemblage of the central radical bearing persistent half rings working surfaces to cheeks of cranks of a shaft.
  1. 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 new persistent half rings.

Replacement of forward half rings should be made only in the event that selection back to correct a situation it is not possible.


  1. By means of approaching оправки, plant on a back pin of a shaft directing bearing, - do not forget to grease preliminary the bearing and a pin with impellent oil. After installation fill the bearing консистентной greasing.
  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.
1 — Back on the engine
2 — Landing labels
  1. With the help щупа лезвийного type make gauging of sizes axial люфтов rods. Compare results of measurements to requirements of Specifications of the Head the Engine, in case of need replace corresponding rods.
  1. 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.