Kia Sportage: Reassembly - Repair procedures
NOTE
- 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.
- The piston front mark and the connecting rod front mark must face the
timing chain side of the engine.
![](images/books/1921/19/index%2027.png)
- Before pressing the piston pin, apply a coat of lubricant oil to the
piston pin outer and connecting rod.
CAUTION
- Take care that piston pin is not damaged dining 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 ~ 22.011 mm (0.8663
~ 0.8665in)
Interference : -0.014mm ~ -0.005mm (0.0006 ~ 0.0002in)
- 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.
CAUTION
Be sure to keep the small end bore, piston pin hole & piston pin from
being damaged and scratched
when inserting the piston pin.
NOTE
Assembling condition
Temperature: piston side 70 to 80C, connecting rod & pin is to be normal
room temperature.
- After inserting the piston pin, set the snap ring of the other side.
CAUTION
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.
- Install the oil ring with coil spring by hand.
- Using a piston ring expander, install the 2 compression rings with the
code mark facing upward.
- Position the piston rings so that the ring ends are as shown.
![3. Install the connecting rod bearings.](images/books/1921/19/index%2028.png)
3. Install the connecting rod bearings.
- Align the bearing claw with the groove of the connecting rod or
connecting rod cap.
- Install the bearings (A) in the connecting rod and connecting rod cap
(B).
![4. Install the main bearings.](images/books/1921/19/index%2029.png)
4. Install the main bearings.
NOTE
Upper bearings have an oil groove of oil holes; Lower bearings do not.
- Align the bearing claw with the claw groove of the cylinder block, push
in the 5 upper bearings (A).
![](images/books/1921/19/index%2030.png)
- 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).](images/books/1921/19/index%2031.png)
6. Install the oil jet (A).
Tightening torque
24.5 ~ 29.4N.m (2.5 ~ 3.0kgf.m, 18.1 ~ 21.7lb-ft)
![7. Place the crankshaft (A) on the cylinder block.](images/books/1921/19/index%2032.png)
7. Place the crankshaft (A) on the cylinder block.
![8. Place the main bearing caps on cylinder block.](images/books/1921/19/index%2033.png)
8. Place the main bearing caps on cylinder block.
9. Install the main bearing cap bolts.
CAUTION
Always use new main bearing cap bolts.
NOTE
- The main bearing cap bolts are tightened in 3 progressive steps.
- If any of the bearing cap bolts in broken or deformed, replace it.
- Apply a light coat of engine oil on the threads and under the bearing
cap bolts.
- 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) + 27.5~31.4N.m (2.8~3.2kgf.m, 20.3~23.1lb-ft)
+ 120~125º
![](images/books/1921/19/index%2034.png)
- Check that the crankshaft turns smoothly.
10. Check crankshaft end play.
11. Install piston and connecting rod assemblies
NOTE
Before installing the pistons, apply a coat of engine oil to the ring
grooves and cylinder bores.
- Remove the connecting rod caps, and slip short sections of rubber hose
over the threaded ends of the
connecting rod bolts.
- 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.
- Stop after the ring compressor pops free, and check the connecting
rod-to-check journal alignment before
pushing the piston into place.
- Apply engine oil to the bolt threads. Using the SST (09221-4A000),
install the rod caps with bearings, and
torque the bolts.
Tightening torque
17.7~21.6N.m (1.8~2.2kgf.m. 13.0~15.9lb-ft) + 88~92º
CAUTION
Always use new connecting rod cap bolts.
NOTE
Maintain downward force on the ring compressor to prevent the lings from
expanding before entering
the cylinder bore.
![12. Apply liquid gasket to the mating surface of cylinder block and ladder](images/books/1921/19/index%2035.png)
12. Apply liquid gasket to the mating surface of cylinder block and ladder
frame.
NOTE
- 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](images/books/1921/19/index%2036.png)
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)
![](images/books/1921/19/index%2037.png)
- Tighten the bolts in order number as shown with the 3 steps.
- Loosen the bolts as reverse tightening order.
- Tighten the bolts in order number as shown with the 3 steps.
![14. Install rear oil seal.](images/books/1921/19/index%2038.png)
14. Install rear oil seal.
- Apply engine oil to a new oil seal lip.
- 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).](images/books/1921/19/index%2039.png)
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.](images/books/1921/19/index%2040.png)
16. Install oil pressure switch.
- Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(B) or equivalent.
- 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).](images/books/1921/19/index%2041.png)
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.](images/books/1921/19/index%2042.png)
18. Install oil level gauge assembly.
- Install a new O-ring on the oil level gauge.
- Apply engine oil on the O-ring.
- 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).](images/books/1921/19/index%2043.png)
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)](images/books/1921/19/index%2044.png)
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 tins 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)
![NOTE](images/books/1921/19/index%2045.png)
NOTE
- 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 thirds to their normal operating levels.
READ NEXT:
Repair procedures
Refilling And Bleeding
WARNING
Never remove the radiator cap when the engine is hot. Serious scalding
could be caused by hot fluid under high
pressure escaping from the radiato
Components and Components Location
Components
Cooling fan assembly
Radiator assembly
Mounting insulator
Radiator mounting
bracket
Radiator upper hose
Radiator lower hose
Res
SEE MORE:
Timer
AUTO STOP display shows the elapsed
time of engine stop by Idle Stop and Go
(ISG) system.
If the ISG does not operate, the reason
for the non-operation is displayed. (if
equipped)
For more details, refer to "Idle Stop and
Go (ISG) system"
Digital speedometer
This d
Component Location
Driver power window switch
Assist power window switch
SJB (Smart Junction Box)
Door lock switch
Tailgate lock actuator & switch
Front door lock actuator & switch
Rear door lock actuator & switch
Power Door Lock Actuator