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#957949 - 10/23/09 04:43 AM Re: FE3 Build Lists * [Re: 2002_Sporty]  
sportagebandit  Offline
Mudrunner
Joined: Mar 2005
Posts: 265
miami, fl
any progress Dennis?


96 SPORTAGE 4 DOOR:1 3/8 body lift:eibach springs & spacers:15x8 rockcrawlers & 31x11.50 super swampers:warn hubs:winch bumper http://www.cardomain.com/ride/2115301

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#957950 - 10/24/09 06:32 PM Re: FE3 Build Lists [Re: sportagebandit]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Ya, things are going slow. I was wanting to put the engine in today but my Probe broke yesterday and I allmost burnt it to the ground. Since thats my daily driver right now I have to work on it. I just need to finish cleaning and painting the valve cover and get the flywheel turned and the engine is ready to go in, that was yesterdays projects before the Probe broke. When a have time I will post the pics of the rebuild.

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957951 - 11/09/09 05:47 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Ok, I'm going to try to post some pics of building the short block. Last time I tried to post the itemized price list I timed out.
Some of the pics are a little blury, I was using my camra phone.

First you need a good helper. (thats Jake)

[Linked Image]

Next after everything is good and clean install the freeze plugs.

[Linked Image]

With a thin film of RTV, I used and old socket and a mallet to knockthem in.

[Linked Image]

Next I installed the Main berrings.

[Linked Image]

Put plastiguage on all the crank journals.

[Linked Image]

Torque all caps to spec, then remove caps and check clearance.

[Linked Image]

If you don't know how long your engine will sit before you fire it up use assembley lub on your bearings, if you plan to fire it up soon you can use engine oil.

[Linked Image]

On your final torque put oil on your main bolts before you torque them to spec.

[Linked Image]

Using a piston push the top ring about half way down the cylinder. Check the end gaps on the rings and if they are to close use a fine file to file them down, mine were all good.

[Linked Image]

Repeat this step with all rings.

[Linked Image]

Check ring clearance in pistons also.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0175.jpg[/img]

There are a few ways to install the rings, I like to just carefully work them in starting with the bottom oil ring and working up.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0179.jpg[/img]

If you have a ring installer you ean use it but I like the other way better. I did clean the pistons better before I finished.

Be sure to set your ring gaps right.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0185.jpg[/img]

Using a piston ring compressor squeeze the rings and put the piston in the hole (be sure the front of the piston is facing the forward).

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0183.jpg[/img]

Using the end of a hammer handle, drive the piston home (be carefull the studs don't camage the crank.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0184.jpg[/img]

Use plastigage on rod caps also.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0186.jpg[/img]

make sure your new oil seal is installed corect and bolt on rear cover.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0187.jpg[/img]

Install oil pump.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0189.jpg[/img]

There, now it's a short block. At this point I masked off everything I didn't want paint on and painted the block a High Temp black. I didn't take pics of installling the head but here it is with the valve cover installed.

[img]http://i260.photobucket.com/albums/ii29/upyourkia/engine%20rebuild/Photo0219.jpg[/img]

I hope this will help someone save some money and try to at least assemble thier engine them self. I got all the specs from the Kia manual and the main trick is to keep everything clean.

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957952 - 11/09/09 05:57 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Be sure to put plenty of oil on your pistons before you install them, I like to dunk them in a container of oil. somehow that pic got lost. Also make sure you torque everything to spec using the proper sequence.

Hope I didn't miss to much.

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957953 - 11/09/09 06:14 AM Re: engine rebuild [Re: DennisThompson]  
Everet  Offline
Body Damage is Cool
Joined: Aug 2006
Posts: 1,224
Silicon Valley, CA
Great info.

Did you polish your valve cover?

If you put short pieces of hose on the con rod bolts, it will protect the crank during assembly.

New oil pump? Did you do anything with the spring to increase tension on the relief valve?

Keep us posted.

Everet <img src="/forums/images/graemlins/patriot.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />


WWW.UPYOURKIA.COM White 96,4x4, man.hubs,K&N filter,3row rad, twin 16" fans, 3" body lift, 4" UPYOURKIA LIFT KIT,265/75 16 TreadWrights on DC2 wheels,140 amp alt. dual batts.

#957954 - 11/09/09 03:17 PM Re: engine rebuild [Re: Everet]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
No I just cleaned it good and painted it. The oil pump is new. I didn't know anyting about relief valve spring so thats a no. It is almost ready to put in but I have been working on the Probe so it will pass inspection in Decamber. I don't want to drive the Kia this winter, I have some rust to fix and don't want it to get worse.

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957955 - 11/10/09 12:15 AM Re: engine rebuild [Re: Everet]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
Thanks for the PICS.....Nice work! <img src="/forums/images/graemlins/kewl.gif" alt="" />


[color:"green"]____________________________________________________________________________________________________[/color]

The Kia Sportage: When I grow up, I want to be a "HUMMER"

#957956 - 11/19/09 01:59 AM Re: engine rebuild [Re: Hydra747]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Cross your fingers <img src="/forums/images/graemlins/smile.gif" alt="" />, I'm planning on putting the engine in Sunday and hope to get it fired up over the Thanksgiving holiday. Nothing else has gone on schedule on this build so wish me luck!

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957957 - 12/01/09 02:01 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I will never set goals again! I was doing great on the Kia engine when I went to install the injectors. The air hoses to the injectors split as I was installing them so I had to order new ones from Kia, they will be in Thursday. I put the engine back in the corner and started on my rear bumper. It's turning out great. I have been taking pics so I will post them when it's done.

Dennis


95 Sportage, gone but not forgotten.
98 Jeep TJ, 4" Zone springs with RC Long arms, Ford 8.8", 4.56 gears & Detroit locker rear, D30, 4.56 & Detroit Trutrack front.

#957958 - 12/01/09 02:03 AM Re: engine rebuild [Re: DennisThompson]  
jaboo5322  Offline
Mudrunner
Joined: Jan 2008
Posts: 305
Rittman Ohio
Keep chuggin. <img src="/forums/images/graemlins/patriot.gif" alt="" />


2001 Sportage, 4" RSG lift, Cragers W/31 10.5 Micky Claws, Warn Manual Hubs, 16 gallon Pro Street Fuel Cell, Custom Snorkel, K&N Filter.
1989 Dodge W250.

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