Engine Block - 2.7L: Overview Kia Sportage II

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1. A/T: remove drive plate.
2. Install engine to engine stand for disassembly (A).
3. Remove timing belt. (See «REMOVAL»(ref-226819-S42443156852006032800000) ).
4. Remove cylinder head. (See «CYLINDER HEAD ASSEMBLY - 2.7L»(ref-226820) )
5. Remove oil level gauge assembly.
6. Remove the alternator. (See «ALTERNATOR»(ref-226828-S05180735342006032800000) ).
7. Remove the air compressor. (See «HEATING, VENTILATION & AIR CONDITIONING»(ref-235431) )
8. Remove the power steering pump bracket (A).
9. Remove water pump. (See «COOLING SYSTEM»(ref-226823) )
10. Remove knock sensors (A).
11. Remove the lower oil pan (A).
12. Remove oil screen. Remove the 2bolts (B), oil screen (A) and gasket.
13. Remove the upper oil pan (A).
14. Check the connecting rod end play. (See «INSPECTION»(ref-226822-S10351156732006032800000) )
15. Remove the connecting rod caps and check oil clearance. (See «INSPECTION»(ref-226822-S10351156732006032800000) )
16. Remove piston and connecting rod assemblies. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
17. Remove front case. (See «LUBRICATION SYSTEM - 2.7L»(ref-226824) )
18. Remove oil seal case. Remove the 3 bolts (B) and oil seal case (A).
19. Check the crankshaft end play. (See «CRANKSHAFT»(ref-226822-S18535427572006032800000) )
20. Remove crankshaft bearing cap and check oil clearance. (See «CONNECTING ROD AND CRANKSHAFT»(ref-226822-S38212867972006032800000) )
21. Lift the crankshaft (A) out of the engine, being careful not to damage journals. NOTE: Arrange the main bearings and trust washers in the correct order.
22. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
23. Remove piston rings. Using a piston ring expender, remove the 2 compression rings. Remove the 2side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
24. Disconnect connecting rod from piston.

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1. Check the connecting rod end play. Using a dial indicator, measure the end play while moving the connecting rod back and forth. Standard end play: 0.1 ~ 0.25mm(0.004 ~ 0.010in.) Maximum end play: 0.4mm(0.016in.) If out-of-tolerance, replace the connecting rod assembly. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Remove the connecting rod cap and bearing half. Clean the crank pin and bearing. Place plastigage across the crank pin. Reinstall the bearing half and cap, and torque the bolts. Tightening torque 16 ~ 20N.m (160 ~ 200kgf.cm, 12 ~ 15lb-ft) + 90° NOTE: Do not turn the crankshaft. Remove the 2bolts, connecting rod cap and bearing half. Measure the plastigage at its widest point. Standard oil clearance 0.018 ~ 0.036mm(0.0007 ~ 0.0014in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the marks are Indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. DISCRIMINATION OF CONNECTING ROD CONNECTING ROD DISCRIMINATION DETAILS CLASS MARK INSIDE DIAMETER 0 A 51.000 ~ 51.006mm (2.0079 ~ 2.0081 in.) 1 B 51.006 ~ 51.012mm (2.0081 ~ 2.0083in.) 2 C 51.012 ~ 51.018mm (2.0083 ~ 2.0086in.) DISCRIMINATION OF CRANKSHAFT CRANKSHAFT DISCRIMINATION DETAILS CLSASS MARK OUTSIDE DIAMETER OF PIN I A 47.994 ~ 48.000mm (1.8895 ~ 1.8898in.) II B 47.988 ~ 47.994mm (1.8893 ~ 1.8895in.) III C 47.982 ~ 47.988mm (1.8890 ~ 1.8893in.) DISCRIMINATION OF CONNECTING ROD BEARING CONNECTING ROD BEARING DISCRIMINATION DETAILS CLASS MARK THICKNESS OF BEARING A BLUE 1.500 ~ 1.503mm (0.0590 ~ 0.0591 in.) B BLACK 1.497 ~ 1.500mm (0.0589 ~ 0.0590in.) C NON 1.494 ~ 1.497mm (0.0588 ~ 0.0589in.) D GREEN 1.491 ~ 1.494mm (0.0587 ~ 0.0588in.) E YELLOW 1.488 ~ 1.491mm (0.0586 ~ 0.0587in.) Selection CONNECTING ROD BEARING AND CRANKSHAFT IDENTIFICATION DETAILS CRANKSHAFT INDENTIFICATION MARK CONNECTING ROD IDENTIFICATION MARK ASSEMBING CLASSIFICATION OF BEARING I (A) 0 (A) E (YELLOW) 1 (B) D (GREEN) 2 (C) C (NONE) II (B) 0 (A) D (GREEN) 1 (B) C (NONE) 2 (C) B (BLACK) III (C) 0 (A) C (NONE) 1 (B) B (BLACK) 2 (C) A (BLUE)
3. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves. Clean each main journal and bearing half with a clean shop tower. Place one strip of plastigage across each main journal. Reinstall the bearings and caps, then torque the bolts. Tightening torque M8 13 ~ 19N.m (130 ~ 190kgf.cm, 10 ~ 14lb-ft) + 90° M10 27 ~ 33N.m (270 ~ 330kgf.cm, 19.5 ~ 24lb-ft) + 90° NOTE: Do not turn the crankshaft. Remove the cap and bearing again, and measure the widest part of the plastigage. Standard oil clearance 0.004 ~ 0.022mm (0.00016 ~ 0.00087in.) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

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1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced. Allowable bend of connecting rod 0.05mm / 100mm (0.0020 in./3.94 in.) or less Allowable twist of connecting rod 0.1mm / 100mm (0.0039 in./3.94 in.) or less Crankshaft bore mark location Letters have been stamped on the end of the block as a mark for the size of each of the 4 main journal bores. Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings. DISCRIMINATION OF CYLINDER BLOCK CYLINDER BLOCK DISCRIMINATION DETAILS CALSS MARK INSIDE DIAMETER a A 66.000 ~ 66.006mm (2.5984 ~ 2.5986in.) b B 66.006 ~ 66.012mm (2.5986 ~ 2.5989in.) c C 66.012 ~ 66.018mm (2.5989 ~ 2.5991 in.) DISCRIMINATION OF CRANKSHAFT CRANKSHAFT DISCRIMINATION DETAILS CLASS MARK OUTSIDE DIAMETER OF JOURNAL I A 61.994 ~ 62.000mm (2.4407 ~ 2.4409in.) II B 61.988 ~ 61.994mm (2.4405 ~ 2.4407in.) III C 61.982 ~ 61.988mm (2.4402 ~ 2.4405in.) DISCRIMINATION OF CRANKSHAFT BEARING CRANKSHAFT BEARING DISCRIMINATION DETAILS CLASS MARK THICKNESS OF BEARING A BLUE 2.007 ~ 2.010mm (0.0790 ~ 0.0791 in.) B BLACK 2.004 ~ 2.007mm (0.0789 ~ 0.0790in.) C NONE 2.001 ~ 2.004mm (0.0788 ~ 0.0789in.) D GREEN 1.998 ~ 2.001mm (0.0787 ~ 0.788in.) E YELLOW 1.995 ~ 1.998mm (0.0785 ~ 0.0787in.) SELECTION CRANKSHAFT AND CRANKSHAFT BORE IDENTIFICATION DETAILS CRANKSHAFT IDENTIFICATION MARK CRANKSHAFT BORE IDENTIFICATION MARK ASSEMBLING CLASSIFICATION OF BEARING I (A) a (A) E (YELLOW) b (B) D (GREEN) c (C) C (NONE) II (B) a (A) D (GREEN) b (B) C (NONE) c (C) B (BLACK) III (C) a (A) C (NONE) b (B) B (BLACK) c (C) A (BLUE)
4. Check crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard end play 0.07 ~ 0.25mm (0.0027 ~ 0.0098in.) Limit: 0.30mm (0.0118in.) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness 2.05 ~ 2.09mm (0.081 ~ 0.082in.)
5. Inspect main journals and crank pins Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter 61.982 ~ 62.000mm (2.4402 ~ 2.4409in.) Crank pin diameter 47.982 ~ 48.000mm (1.8890 ~ 1.8898in.)

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1. Remove gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Standard: Less than 0.03mm(0.0012 in.) Limit: 0.05 mm ( 0.0020 in.)
4. Inspect cylinder bore diameter Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder liner.
5. Inspect cylinder bore diameter Using a cylinder bore gauge, measure the cylinder bore diameter at position A, B and C in the thrust and axial directions. Standard diameter 86.70 ~ 86.73mm (3.4134 ~ 3.4145in.)
6. Check the cylinder bore size code (A) on the cylinder block bottom face. CYLINDER BORE INNER DIAMETER SPECIFICATIONS Class Cylinder bore inner diameter Size code A 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) A B 86.71 ~ 86.72mm (3.4137 ~ 3.4141 in.) B C 86.72 ~ 86.73mm (3.4141 ~ 3.4145in.) C
7. Check the piston size code (A) on the piston top face. NOTE: Stamp the grade mark of basic diameter with rubber stamp. PISTON DIAMETER SPECIFICATIONS Class Piston diameter Size code A 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) A B 86.69 ~ 86.70mm (3.4130 ~ 3.4133in.) None C 86.70 ~ 86.71mm (3.4133 ~ 3.4137in.) C
8. Select the piston related to cylinder bore class. Clearance: 0.01 ~ 0.03mm (0.0004 ~ 0.0012in.)