Engine Mechanical: Overhaul Kia Sorento I рестайлинг

DISASSEMBLY

Note. Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original position.

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1. Remove MLAs (A).
2. Remove valves. Using SST (09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock. Remove the spring retainer. Remove the valve spring. Remove the valve. Using SST (09222-29000), remove the valve stem seal. NOTE: Do not reuse old valve stem seals.
3. Remove OCV (A).

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1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard: Less than 0.05 mm (0.002 in.) [Less than 0.02 mm (0.0008 in.)/150x150] Flatness of manifold gasket surface Standard: Less than 0.03 mm (0.001in)/110x110
2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

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1. Inspect valve stems and valve guides. Using a caliper gauge, measure the inside diameter of the valve guide. Valve guide I.D. Intake / Exhaust: 5.500-5.512 mm (0.216-0.217 in.) Using a micrometer, measure the diameter of the valve stem. Valve stem O.D. Intake: 5.465-5.480 mm (0.2151-0.2157 in.) Exhaust: 5.458-5.470 mm (0.2149-0.2153 in.) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement. Valve stem-to-guide clearance [Standard] Intake: 0.020-0.047 mm (0.0008-0.0018 in.) Exhaust: 0.030-0.054 mm (0.0012-0.0021 in.) [Limit] Intake: 0.07 mm (0.0027 in.) Exhaust: 0.09 mm (0.0035 in.)
2. Inspect valves. Check the valve is ground to the correct valve face angle. Check that the surface of the valve for wear. If the valve face is worn, replace the valve. Check the valve head margin thickness. If the margin thickness is less than minimum, replace the valve. Margin [Standard] Intake: 1.56-1.86 mm(0.06142-0.07323 in.) Exhaust: 1.73-2.03 mm(0.06811-0.07992 in.) Check the valve length. Length Intake: 105.27 mm (4.1445in) Exhaust: 105.50 mm (4.1535in) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect valve seats Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace cylinder head. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect valve springs. Using a steel square, measure the out-of-square of the valve spring. Using a vernier calipers, measure the free length of the valve spring. Valve spring [Standard] Free height: 43.86 mm (1.7267 in.) Out-of-square: 1.5°

REASSEMBLY

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones.

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1. Install valves. Using SST (09222-3C100), push in a new oil seal. NOTE: Do not reuse old valve stem seals. Incorrect installation of the seal could result in oil leakage past the valve guides. Install the valve, valve spring and spring retainer. NOTE: Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer. Using the SST (09222-3K000, 09222-3C300), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
2. Install MLAs. Check that the MLA rotates smoothly by hand. NOTE: MLA can be reinstalled in its original position.
3. Install OCV (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: To install OCV with gray colored connector into RH bank. To install OCV with black colored connector into LH bank. CAUTION: Do not reuse the OCV when dropped. Keep clean the OCV. Do not hold the OCV sleeve during servicing. When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.

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.

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1. Assemble piston and connecting rod. Use a hydraulic press for installation. The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install piston rings. Install the oil ring spacer and 2 side rails 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 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 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 4 upper bearings (A). Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.
5. Install 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. Place crankshaft on the cylinder block.
7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown. Tightening torque Main bearing cap bolt 49.00 N.m (5.0 kgf.m, 36.16 lb-ft) + 90° (1-8) 19.60 N.m (2.0 kgf.m, 14.46 lb-ft) + 120° (9-16) 29.40-31.36 N.m (3.0-3.2 kgf.m, 21.70-23.14 lb-ft) (17-22) NOTE: Always use new main bearing cap bolt. If any of the bearing cap bolts in broken or deformed, replace it. Use SST (09221-4A000), install main bearing cap bolts. Check that the crankshaft turns smoothly.
9. Check crankshaft end play.
10. Install piston and connecting rod assemblies. NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores. 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. Install the rod caps with bearings, and torque the bolts. Tightening torque 19.6 N.m (2.0 kgf.m, 14.46 lb-ft) + 90° Use SST (09221-4A000), install connecting rod bearing cap bolts. NOTE: Always use new connecting rod bearing cap bolt. Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
11. Check the connecting rod end play.
12. Install oil drain cover. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.67 lb-ft) NOTE: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant Be assembling oil drain cover, the liquid sealant TB1217H should be applied oil drain cover. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
13. Install rear oil seal case. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.67 lb-ft) NOTE: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant Be assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
14. Using SST (09231-3C200, 09231-H1100), install rear oil seal.
15. Install baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
16. Install upper oil pan. Using a gasket scraper, remove all the old packing material from the gasket surfaces. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5 mm (0.1 in.) CAUTION: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant When applying sealant gasket, sealant must not be protruded into the inside of oil pan. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. Install oil pan. Uniformly tighten the bolts in several passes. Tightening torque 9.80-1176 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) After assembly, wait at least 30 minutes before filling the engine with oil.
17. Install knock sensor. Tightening torque 15.68-23.52 N.m (1.6-2.4 kgf.m, 11.57-17.36 lb-ft)
18. Install drive plate. Tightening torque 71.54-75.46 N.m (7.3-7.7 kgf.m, 52.80-55.69 lb-ft)

WATER TEMPERATURE CONTROL ASSEMBLY

Note. Make clean the contact face before assembly.

1. Install water temperature control assembly (A) and new gasket. Tightening torque 19.6-23.52 N.m (2.0-2.4 kgf.m, 14.5-17.36 lb-ft) NOTE: Use new O-rings (C) when reassembling.
2. Connect water hoses to the water temperature control assembly.
3. Install the fuel pipe (A).
4. Connect WTS connector.
5. Connect the RH/LH cooling pipes (A, B).
6. Install the battery assembly (A).
7. Install the automatic transaxle oil gauge.
8. Install air cleaner assembly.
9. Fill with engine coolant.
10. Start engine and check for leaks.
11. Recheck engine coolant level.

OIL FILTER ASSEMBLY

1. Install oil filter body and new O-rings. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: All rubber gasket must be no damaged by assembling parts. Be careful of the knock sensor connector. Always use a new O-ring
2. Install oil filter body cover (B) and new gasket on the oil filter body (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
3. Install the water temperature control assembly.
4. Connect the water hoses on the water temperature control assembly.
5. Connect the oil pressure switch connector.
6. Install the intake manifold and surge tank.
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Recheck engine coolant level.

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1. Remove the engine cover.
2. Remove the engine room resonator (A).
3. After disconnecting the MAF sensor connector (A) and the breather hose (B), remove the air cleaner assembly (C).
4. Disconnect the other breather hose (A), the Purge Control Solenoid Valve (PCSV) hose, the Positive Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses (D) and connector (E).
5. Remove the wiring over the surge tank. Disconnect the injection harness connector (A). Disconnect the camshaft position sensor (CMP) harness connector (B). Disconnect the ground line (C). Disconnect the ignition coil harness connector (D). Disconnect the condenser connector (E). Disconnect the variable induction system (VIS) solenoid valve connector (G). Disconnect the oil control valve (OCV) harness connector (F). Disconnect the injector wiring (H) and ignition coil wiring (I).
6. Disconnect the fuel hose tube (A).
7. Remove heater hose (A) and disconnect the brake vacuum hose (B).
8. Disconnect the surge tank stay.
9. Remove the surge tank.
10. Disconnect the injector connectors.
11. Disconnect the water hose on intake manifold from the nipple on the chain cover.
12. Remove the delivery pipe and intake manifold as an assembly. NOTE: Except such cases as defects of injectors or pipe, do not disassemble a delivery pipe from an intake manifold because it is one of the fuel system parts, or you may have some problem in fuel system.
13. Install intake manifold and new gasket on the cylinder head. Tightening torque 1st: 3.9-5.9 N.m (0.4-0.6 kgf.m, 2.9-4.3 lb-ft) 2nd Bolt: 26.5-31.4 N.m (2.7-3.2 kgf.m, 19.5-23.1 lb-ft) Nut: 18.6-23.5 N.m (1.9-2.4 kgf.m, 13.7-17.4 lb-ft) 3rd: Repeat 2nd step twice or move. NOTE: Be careful of the installation direction. a-h: 1st step order 1-8: 2nd step order
14. Connect the water hose on intake manifold to the nipple on the chain cover.
15. Install delivery pipe. Refer to Delivery pipe in «GENERAL (FUEL SYSTEM)»(ref-278797) .
16. Install the surge tank and new gasket on the intake manifold. Tightening torque Long bolt: 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) Short bolt, nut: 18.6-23.5 N.m (1.9-2.4 kgf.m, 13.7-17.4 lb-ft)
17. Connect heater hose (A) and the brake vacuum hose (B).
18. Connect the fuel hose tube (A).
19. Connect the wiring over the surge tank. Connect the injection harness connector (A) Connect the camshaft position sensor (CMP) harness connector (B). Connect the ground lines (C). Connect the ignition coil harness connector (D). Connect the condenser connector (E). Connect the variable induction system (VIS) solenoid valve connector (G). Connect the oil control valve (OCV) harness connector (F).
20. Connect the other breather hose (A), the Positive Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses (D), ETC connector (E).
21. After connecting the MAF sensor connector (A) and the breather hose (B), install the air cleaner assembly (C).
22. Install the engine room resonator (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
23. Remove the engine cover (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)

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