KIA of Sportazh - Kia Sportage
Governing bodies and operation receptions
Current leaving and service
Engine
   Check of kompressionny pressure, assessment of a condition of cylinders
   Engine check by means of the vacuum gage
   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 a drive of GRM
      Check and adjustment of klapanny gaps
      Removal and installation of the inlet pipeline and final collector
      Service of a head of cylinders and components of the gas-distributing mechanism
      Dismantling and assembly of the block of cylinders, service of components
      Removal and installation of the pallet of a case
      Removal, installation and service of the oil pump
      Removal and installation of a maslookhladitel
      Removal and flywheel installation
      Removal and installation of masloraspylitel
      Replacement of epiploons of a cranked shaft
Systems of cooling, heating, ventilation and air conditioning
Power supply systems, managements of engine/decrease in toxicity of the fulfilled gases and production of the fulfilled gases
Systems of electric equipment of the engine
Five-step manual box of gear shifting
Automatic transmission
Transmission line
Brake system
Suspension bracket and steering
Body
Onboard electric equipment
Control body sizes
Schemes of electric connections



Kia Sportage>> Engine>> Diesel models>> Dismantling and assembly of the block of cylinders, service of components

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

Dismantle and installation of a cranked shaft and shatunno-piston assemblies 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 of the shatunny 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. Section Removal and engine installation).
  2. Remove a head of cylinders (see. Section Service of a head of cylinders and components of the gas-distributing mechanism).
  3. Remove the oil pump (see. Section Removal and installation of the pallet of a case).
  4. Remove the pallet of a case and a flywheel / a driving disk (see. Sections Dismantling and assembly of the block of cylinders, service of components and Removal and installation of a maslookhladitel).
  5. Remove a back epiploon with a cover (see. Section Removal and installation of masloraspylitel).
  6. Turn out fixing bolts and remove covers of radical bearings with collecting with loose leaves.
  7. Turn out fixing bolts and uncover the bottom head of the first rod assembled with the loose leaf. Rest against a rod head the handle of a hammer and, pushing shatunno-piston assembly up, take it from the cylinder.
  8. Operating in a similar manner, take the remained assemblies.
  9. For the purpose of confusion prevention at check of a condition of components at once establish on the former places of a cover of shatunny and radical bearings of a cranked shaft assembled with loose leaves and fix them 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 molding of the block. Check each cylinder on existence of cracks, задиров and other mechanical damages.
  1. Operating in the manner similar to described in the Section Service of a head of cylinders and components of the gas-distributing mechanism, estimate extent of violation 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 case 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 a konusnost and ovality. Results write down. By subtraction from the maximum result minimum define degree of wear of the cylinder and if it exceeds limiting admissible value (see. The Engine), cylinders it is necessary to chisel specifications of Head till the next repair size. In conclusion of a mirror of cylinders should be отхонингованы, - act according to the instructions attached to special honingovochny sets.
  1. With special vertical drill remove the step wear of cylinders left by the top kompressionny ring at 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 identification of cracks, задиров and other mechanical damages prepare replacement.
  4. Measure diameter of each piston in the 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 the next repair size.
1 — the Control size

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

  1. Check piston rings on existence of signs of excessive wear, cracks, chips and other mechanical damages. In case of need make replacement.
  1. Serially filling piston rings in the cylinder and pushing them the piston bottom in the lower part of the last (position NMT of the piston), measure sizes of gaps in locks of rings. Compare results of measurements to requirements of Specifications of 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 the ring/piston.
1 — the Top kompressionny ring
2 — the Second kompressionny and maslosjemny rings

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


  1. At the special stand believe rods on existence of signs of a bend and twisting. At excess by results of measurements of limiting admissible values replace defective components.
  1. By measurement of the 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 worn-out plugs.
  2. Squeezing of the plug is made by means of an opravka in diameter of 27 ÷ 27.5 mm.
  3. Before a press fitting grease the new plug and a rod with pure impellent oil. Track correctness of combination of lubricant openings. After a press fitting develop the plug development to nominal rate of internal diameter.
Zapressovyvaniye and development of the plug (2) of the top head of a rod, - track correctness of combination of oil openings (1).
  1. Attentively study a condition of a cranked shaft. Check his root and shatunny necks on existence задиров, traces of an overheat and other mechanical damages. Make sure of absence of violations of passableness of oil openings.
  1. Having laid a shaft in prisms, check it on bend existence by means of DTI measuring instrument.
  1. Measure diameters of necks, estimate sizes of their konusnost and ovality. If wear 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 detection of defects prepare a replaceable set. Spread out loose leaves as installation them to the engine.

Assembly

 PERFORMANCE ORDER

  1. Before the beginning of assembly make sure of absoluteness of purity of all components.
  1. Warm up the piston to temperature of 50 ÷ 70 °C. Grease the shatunny plug and openings in piston inflow by pure oil, then fill in the piston one of lock rings. Get a rod in the piston and fix it a piston finger and establish the second lock ring, - track correctness of an arrangement from each other an oil opening on a rod and «F» labels on the piston. Operating in a similar manner, mount all shatunno-piston assemblies.
  1. Plant on pistons the picked-up earlier piston rings: at first in the bottom flute of the piston the dilator of a maslosjemny ring is established, then its working sections are got. Further, in the remained flutes the bottom and top kompressionny rings (do not mix a ring - they differ in a section form) refuel, - track correctness of placement of rings.
1 — the Identification label
2 — the Piston ring
3 — Up
4 — the Top kompressionny ring
5 — the Second kompressionny ring
6 — Working section of a maslosjemny ring

It is necessary to establish rings the marked letter of "Y" the party up.

  1. Develop the rings planted on pistons locks in the specified directions.
1 — the Top ring and a spring dilator of a maslosjemny ring
2 — the Second kompressionny ring
3 — Working sections of a maslosjemny ring
  1. Accurately fill shatunno-piston assemblies 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 a special opravka; pushing through of pistons in cylinders is best of all for making the hammer handle. Track, that pistons were established by labels in the form of «F» letters forward on the engine.

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

  1. Plant in the block of cylinders masloraspylitel 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, having completely 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 Plastigage set for definition of working gaps in sliding bearings.

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

  1. Wipe backs of loose leaves of bearings and their bed in covers, then establish the last, having tracked correctness of placement and, operating strictly in a certain order, tighten bolts of their fastening with demanded effort.
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 a set of Plastigage, define sizes of gaps 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 assembly 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 size axial люфта a cranked shaft and freedom of its provorachivaniye. Compare result of measurement to requirements of Specifications of Head the Engine, in case of need pick up new persistent half rings.

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


  1. By means of a suitable opravka, plant on a back pin of a shaft directing bearing, - do not forget to grease previously the bearing and a pin with impellent oil. After installation fill the bearing konsistentny greasing.
  1. Having planted the bottom heads of rods on shatunny necks of a shaft, make measurement of working gaps in shatunny bearings, - act 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 lezviyny type make measurement of sizes axial люфтов rods. Compare results of measurements to requirements of Specifications of Head the Engine, in case of need replace the corresponding rods.
  1. Finalize shatunny 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. Further installation make as it should be, the return to an order of dismantle of components.