Engine Block - 2.7L: Other Kia Sportage II

BORING CYLINDER

1. Oversize pistons should be selected according to the largest bore cylinder. PISTONS BORE SIZE SPECIFICATIONS Identification Mark Size 0.25 0.25mm (0.010in.) 0.50 0.50mm (0.0250in.) NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size. New bore size = Piston O.D + 0.01 to 0.03mm (0.0004 to 0.0012 in.) (Clearance between piston and cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size. CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder. Standard: 0.01 ~ 0.03mm (0.0004 ~ 0.0012 in.) NOTE: When boring the cylinders, finish all of the cylinders to the same oversize. Do not bore only one cylinder to the oversize.

Scheme 376

Scheme 377

Scheme 378

1. Clean piston Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 38.5mm (1.516in.) from the top land of the piston. Standard diameter 86.68 ~ 86.71mm (3.4126 ~ 3.4138in.)
3. Calculate the difference between the cylinder bore diameter and the piston diameter. Piston-to-cylinder clearance 0.01 ~ 0.03mm(0.0004 ~ 0.0012in.)
4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Piston ring side clearance No. 1: 0.04 ~ 0.08 mm (0.0016 ~ 0.0031 in.) No. 2: 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.) Limit No. 1: 0.1mm (0.004in.) No. 2: 0.1mm (0.004in.) If the clearance is greater than maximum, replace the piston.
5. Inspect piston ring end gap. To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits on «CYLINDER BLOCK»(ref-226822-S34511777342006032800000) , If the bore is over the service limit, the cylinder block must be rebored. (See «CYLINDER BLOCK»(ref-226822-S34511777342006032800000) ). Piston ring end gap Standard No.1: 0.20 ~ 0.35mm (0.0079 ~ 0.0138in.) No.2: 0.37 ~ 0.52mm (0.0146 ~ 0.0205in.) Limit Oil ring: 0.2 ~ 0.7mm (0.0079 ~ 0.0276in.)

Scheme 379

1. Measure the diameter of the piston pin. Piston pin diameter 21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance 0.007 ~ 0.022mm (0.00027 ~ 0.00086in.)
3. Check the difference between the piston pin diameter and the connecting rod small end diameter. Piston pin-to-connecting rod interference 0.016 ~ 0.033mm (0.00063 ~ 0.00130in.)

Scheme 380

Scheme 381

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed, replace the switch.
3. If there is no continuity when a 50kpa (7psi) vacuum is applied through the oil hole, the switch is operating properly. Check for air leakage. If air leaks, the diaphragm is broken. Replace it.