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#957929 - 08/07/09 07:48 PM engine rebuild *  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I have most of the parts to start assembling my engine but the rings are on back order and I am having a hard time finding head bolts. It's not like rebuilding a SB Chevy, I just can't find a kit with everything in it. Most of my parts I got off ebay, some at Summit Racing and others from the Kia dealer which is where I will look next for the head bolts. I was going to go to the dealer first on them but my boy got some ARP studs for his so I contacted them for bolts with no luck. The studs are expensive. When I start I will compile a list on what I got where. While the Kia has been down I bought new tierods and tierod ends, finished my rocker guards (but not installed yet) and I started building a rear bumper. I also hauled it down to the carwash and cleaned under the hood. I still need to install the rear SLD and finish the fan install on the radiator.

I have been working 5-10s with lots of search & rescure training on the weekends so I have not had a lot of time. I do have a lot of vacation so when I have everything I am planning on taking a full week off to see how far I can get on everything. When that happends I will use this thread to post details and pics.

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.

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#957930 - 09/03/09 11:56 PM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I have'nt started yet, no time off I just wanted to give you guys a little heads up. Listed on ebay is a pair of ignition coils for under $80.00 (pay it now) I ordered a pair and waited about 2 weeks with no word from the seller, I sent him a measage and he said they where in customs. It's been alost 2 months now, he never contacts me, I have to try to contact him. I am tring to get my money back now. He can't get them to me yet he still has them listed. So to save a head eche don't buy them, I found almost the same price at Rock Auto.

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.

#957931 - 09/04/09 02:46 AM Re: engine rebuild [Re: DennisThompson]  
Everet  Offline
Body Damage is Cool
Joined: Aug 2006
Posts: 1,224
Silicon Valley, CA
RockAuto Rocks!!!

Did you ever come up with a source for head bolts?

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.

#957932 - 09/04/09 04:40 AM Re: engine rebuild [Re: Everet]  
DEFBOY35  Offline
Rock Warrior
Joined: Aug 2006
Posts: 598
Alberta, Canada
Quote
RockAuto Rocks!!!

Did you ever come up with a source for head bolts?

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="" />


i believe arp has them


2000 SPORTY, DEF BOY customs, mmm....lockers, mmm... gears, mmm... double transfer case, mmm... stroker
http://www.cardomain.com/ride/2377991

#957933 - 09/04/09 12:25 PM Re: engine rebuild [Re: DEFBOY35]  
homerdog  Offline
Mudrunner
Joined: Dec 2007
Posts: 316
Michigan
Did you try a machine shop for head bolts?


2001 Sportage, TJ 106's, Everet spacers and bumpstops, Bilstein shocks on the rear, cone filter, Crager wheels, 235-75-15 Goodyear tires. Custom front winch bumper by Dave Scott. Currently DOA, but it is a work in progress.
2011 Kia Forte EX

#957934 - 09/05/09 01:09 AM Re: engine rebuild [Re: homerdog]  
jays2001  Offline
Wheeler
Joined: Feb 2008
Posts: 244
mendon. illinois
for shipping price and what ever it takes to get them to you you can have my old ones replaced them when had engine trouble and turned out to be wires.


01 w/31 in. mtr,winch,elec.fan ,4 in.suspension lift and 4in. body lift,front and rear hitch. NOT ENOUGH POWER so V8 and solid axles coming soon.2013

#957935 - 09/05/09 06:20 AM Re: engine rebuild [Re: jays2001]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
On the head bolts I went with my first choice, The dealer. They were $5.25 each. I contacted ARP and they needed a bunch of measurments off my head to see if some for another engine would work, they did not have a part# for a Sportsge or a Mazda FE3. When my boy got his ARPs for his FE3 he sent them a stock bolt and he paid over $14.00 each for studs. I hope to start assembling soon.

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.

#957936 - 09/05/09 06:25 AM Re: engine rebuild [Re: jays2001]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
My old ones are still good, I just want everything new and keep spares on hand. Thanks for the offer though. You just reminded me I still need wires <img src="/forums/images/graemlins/smile.gif" alt="" />.

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.

#957937 - 09/05/09 11:01 PM Re: engine rebuild [Re: DennisThompson]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
Hey Dennis,
Are u gonna re-build stock?
How much are u looking at for cost?
Thanks,

Mike <img src="/forums/images/graemlins/kewl.gif" alt="" />


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

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

#957938 - 09/05/09 11:15 PM Re: engine rebuild [Re: Hydra747]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Ya, I'm going stock for now. My boy and his freind are going to help me with a Turbo later, they just don't know it yet. I have yet to add up all my parts but I have about $350.00 in machine work on the block and head. I'm thinking I have another $500.00 in parts for the rebuild not including the clutch. When I get brave I will add it all up.

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.

#957939 - 09/06/09 08:49 AM Re: engine rebuild [Re: DennisThompson]  
Nukeiridium  Offline
Body Damage is Cool
Joined: Aug 2002
Posts: 1,136
Mesa, Arizona
Quote
My old ones are still good, I just want everything new and keep spares on hand. Thanks for the offer though. You just reminded me I still need wires <img src="/forums/images/graemlins/smile.gif" alt="" />.

Dennis


IMO it's nice to replace the head bolts if you can, we were doing the head gasket on my brother's car and had the whole dang thing back together and torqueing the head bolts down, and on the very last torque step of the very last head bolt, PING! Bolt broke off below the level of the head gasket and at an angle, took us an hour to drill into the hard steel bolt and get it out with an Easy Out. Not to mention the time it took to re-do the whole job again with new bolts...

Not much fun! Made me want to get new head bolts every time.

FYI, that job was cursed anyway... On the second time, with the new head bolts, I let my brother put the head gasket on the block while I was doing another part, and I didn't check his work, then after we put the whole thing back together and were adding water to the radiator, we hear this trickle of water running out of the block...

Turns out my bro had put the head gasket on upside down (yep it fit that way) and the water passages didn't line up so water was pouring out. Had to take it apart and do it AGAIN. We pretty much ended up changing the head gasket a total of 3 times in one night because of stupidity (not replacing worn head bolts and putting gasket on wrong). That was a long night!

I will never let him live that one down, putting the head gasket on upside down when the top of the gasket says "TOP" in half-inch letters <img src="/forums/images/graemlins/smile.gif" alt="" />

Last edited by Nukeiridium; 09/06/09 08:53 AM.

2002 Sportage 4dr 4x4 soon to undergo an Extreme Makeover!

#957940 - 09/06/09 06:14 PM Re: engine rebuild [Re: Nukeiridium]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I was talking ignition coils there. Most Head bolts are torque to yeild, which meens one time use. The machine shop told me that the rod and main bolts on the FE3 are fine to reuse. He was amazed on how beefy the internals are on the Mazda F2s and FE3s are.

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.

#957941 - 09/13/09 02:44 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Got my new coils from Rock Auto yesterday and also got my refund for the pair I ordered on ebay that never came. I still need to find time to put this thing back together, I'm just greatfull my boy was able to put together such a reliable Probe for me. I have put about 15,000 miles on it since I killed the Kia and the only thing I have had to do is a brake master cylinder (knock on wood). I need to get it done soon, I NEED to go wheelin.

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.

#957942 - 09/19/09 04:03 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I just typed up a itemized list of how much I spent and what cost what but when I went to send it the site timed out and erased it all. So I will just say for now that with machining, parts and accessers I am at $1212.00 with at least $200.00 left to go. Still cheap compaired to having a shop rebuild it or a new or used engine bacause most of that I still would have had to get. I started putting it together today with lots of pics, I will post them when it's done. I won't have time tommorrow to work on it but maybe Sunday.

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.

#957943 - 09/19/09 04:26 PM Re: engine rebuild [Re: DennisThompson]  
sportagebandit  Offline
Mudrunner
Joined: Mar 2005
Posts: 265
miami, fl
went mudding at L-cross ranches two weekends ago, had mud up to the door handles and up over the hood. thank got i fabbed a snorkel. but none the less i have rod knock now (no water in oil) and gotta figure out wether or not to rebuild or do an engine swap.....


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

#957944 - 10/10/09 02:05 PM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I got all of next week off to try to finish the Kia. The short block is done, just need to put on the head and everything on the outside of the block. I remembered the other day the starter was giving me fits last winter. I think it was a lifetime warantee. I will post all the pics of the assembly when I finish.

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.

#957945 - 10/10/09 02:17 PM Re: engine rebuild [Re: DennisThompson]  
fokion  Offline
Body Damage is Cool
Joined: Jul 2003
Posts: 1,476
Athens Greece
Dennis did you happen to look the mazda B2200 possibility (crank and rods I mean)??

Last edited by fokion; 10/10/09 02:18 PM.

'96 4d mechanicaly stock so far, rims, spoiler, Cooper AT tyres, Factory LSD, Manual Warn Hubs, handmade exaust, ELECTRIC FAN!!! 3,1'' Lift, PALM GPS
http://members.cardomain.com/fokion

#957946 - 10/10/09 10:59 PM Re: engine rebuild [Re: fokion]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I was thinking about the Probe crank but after my boy spun a bearning the 2nd time in his stroker I decided to stay stock. The machine shop found the fix but I was already committed. I do plan on a turbo later down the road.

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.

#957947 - 10/13/09 10:35 PM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
So I'm off this week to work on the Kia. So far I have my mother-in-laws swamp cooler winterized and post holes dug and the fence posts planted in my back yard. I finaly got to the Kia, went to put the head on and Kia ordered me the wrong head bolts. I don't know why I didn't check that out when I got them but I'm dead in the water now. Tomorrow I will start on the tie rod and tie rod ends, sway bar links, front brakes and maybe start on the rear bumper if I have time.

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.

#957948 - 10/14/09 01:13 PM FE3 Build Lists [Re: DennisThompson]  
2002_Sporty  Offline
Mudrunner
Joined: Dec 2008
Posts: 336
Fairbanks Alaska
Here are a few lists of mazda guys building FE3's
http://www.mx6.com/forums/fe-dohc/184255-fe3-build-lists.html


2002 4dr Kia Sportage 4X4
Tires:235/75/15, Wheels: Black 15x8 Steel ProComp 2.5" B.S., Hubs:Warn Manual, Lift:3" UPYOURKIA, Trailer Hitch, Cargo Rack, Clinometer.

#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

#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.

#957959 - 12/01/09 11:47 PM Re: engine rebuild [Re: jaboo5322]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
What exhaust components are you looking at?

Last edited by DamKia; 05/13/10 03:54 AM.

#957960 - 12/02/09 05:12 AM Re: engine rebuild [Re: Hydra747]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I think Jake would like Katie! It's the hoses that go from the injectors to the head I need. I did the exhaust just before the engine gave out. it's getting closer though, can't wait to here it run!

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.

#957961 - 12/20/09 07:56 PM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Well, I think I got the Probe ready to pass inspection so after Cristmas it's back to the Kia. This has got to be the longest engine rebuild in history. I just put a windshield in and built an exhaust for the Probe. I had enough pipe left over from the Kia's exhaust to do the whole car, I had a new MagnaFlow left over from my $100.00 Bronco that I sold before I got to the exhaust so I did a whole 2 1/2" cat back on the Probe for about $10.00 in gaskets and hangers. I think I am still under a $600.00 total in the Probe and I put over 20,000 miles in it allready and hit 1 deer, not bad for cheep transportation. Just keeping you up to date on my (none) progress on the Kia. I'll let you know when it makes noise.

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.

#957962 - 12/20/09 09:29 PM Re: engine rebuild [Re: DennisThompson]  
Everet  Offline
Body Damage is Cool
Joined: Aug 2006
Posts: 1,224
Silicon Valley, CA
You should have some nice venison steaks out of the deer so hitting it wasn't a total loss <img src="/forums/images/graemlins/kewl.gif" alt="" />
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.

#957963 - 12/20/09 09:40 PM Re: engine rebuild [Re: Everet]  
69442  Offline
Rock Warrior
Joined: Mar 2009
Posts: 587
SEATTLE USA
Quote
You should have some nice venison steaks out of the deer so hitting it wasn't a total loss <img src="/forums/images/graemlins/kewl.gif" alt="" />
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="" />


If the deer can not be repaired back to pre-accident condition, technically it would be considered a total loss.

Sounds like Dennis kept the pre-tenderized salvage (steaks), i like mine medium rare please <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/barf.gif" alt="" />


LIFT OR BUST! 2001 Sportage EX 4dr 4WD with 300,210 miles & counting .....
____o_o
l_l_l\___\___
l----[o]==[o]
l----==[--]==
()_)()_)--()_)

#957964 - 12/20/09 10:06 PM Re: engine rebuild [Re: 69442]  
jaboo5322  Offline
Mudrunner
Joined: Jan 2008
Posts: 305
Rittman Ohio
Yes please. <img src="/forums/images/graemlins/drunk.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.

#957965 - 12/21/09 01:43 PM Re: engine rebuild [Re: jaboo5322]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Deer survived, just a little sore. I was already slowed down for the rest of the herd, he was just a stragler, I got back on the gas a little to soon. All it did was brake the rod on the flip-up head light and push the bumper and grill into the hood, a new rod and a crow bar was all in took and the Probe was ok.

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.

#957966 - 12/21/09 03:18 PM Re: engine rebuild [Re: DennisThompson]  
69442  Offline
Rock Warrior
Joined: Mar 2009
Posts: 587
SEATTLE USA
Deer 1 - probe 0

<img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" />


#957967 - 12/23/09 01:41 AM Re: engine rebuild [Re: DennisThompson]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
Quote


[Linked Image]



Nice shot and work Dennis! <img src="/forums/images/graemlins/kewl.gif" alt="" />

There are 15 bolts to take off of the valve cover....Cause I tried to take off the cam bolts in the back (Everet called and saved my butt)! <img src="/forums/images/graemlins/cheers.gif" alt="" />


What kinda paint did you use?

Did u use break cleaner to remove some of that grease/oil off the outside?

BTW: I purchased all new bolts for the valve cover cause they tend to errode/corrode after time and especially with the heat.

P.S. Some of the high temp silicone prolly ended up mixing with the oil after I performed the gasket Job.........Would you just take the pan off and use a new gasket?

P.S.S. Do you think that it would cause any problems?????


Thanks Denny!

Mikey <img src="/forums/images/graemlins/patriot.gif" alt="" />


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

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

#957968 - 12/24/09 12:36 AM Re: engine rebuild [Re: Hydra747]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I used brake cleaner and a wire brush to clean it up, then I used high heat red and painted over the letters, after that I taped off the letters with masking tape and cut them out with an Exacto knife and painted the rest with high heat silver. The paint was Dupli-Color ceramic engine enamel ratted at 500 F. About 3 coats of each color, the block was painted with the same paint, only black.

As long as the RTV doesn't block an oil passage you should be ok. I used RTV only on the oil pan, The gasket kit only came with 1 gasket and with the windage tray you need 2. On the valve cover I would just use a new gasket.

Dennis

Last edited by DennisThompson; 12/24/09 12:41 AM.

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.

#957969 - 02/20/10 02:01 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I know you guys won't believe this but after almost a year and 3 months there is an engine resting between the frame rails of my Kia. I will work on hooking up all the hoses and electral tomorrow. I can't believe how easy it slid into place. It took 1 try and about 5 minutes to align it up to the trans, the clutch alignment tool must have worked. I spent most of my time today looking for a part that didn't exist. When I pulled the engine out I thought I bent the dip stick bracket so I straitend it out with a hammer, when I tried to put it together I couldn't get it to fit around the cooling inlet pipe and thought it needed a spacer. After I bent the bracket back it all fit, what a dummy <img src="/forums/images/graemlins/confused.gif" alt="" /> I was. Well wish my luck on hearing noise tomorrow.

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.

#957970 - 02/20/10 02:11 AM Re: engine rebuild *DELETED* [Re: DennisThompson]  
jaboo5322  Offline
Mudrunner
Joined: Jan 2008
Posts: 305
Rittman Ohio
Post deleted by jaboo5322

Last edited by jaboo5322; 02/28/10 10:24 PM.

#957971 - 02/20/10 02:18 AM Re: engine rebuild [Re: jaboo5322]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *

Last edited by DamKia; 05/13/10 03:54 AM.

#957972 - 02/20/10 05:23 AM Re: engine rebuild [Re: DennisThompson]  
69442  Offline
Rock Warrior
Joined: Mar 2009
Posts: 587
SEATTLE USA
...

Last edited by DamKia; 05/13/10 03:55 AM.

#957973 - 02/20/10 07:24 AM Re: engine rebuild [Re: DennisThompson]  
blitz  Offline
Wheeler
Joined: Dec 2004
Posts: 240
got my fingers crossed for you man. i think it will run great. <img src="/forums/images/graemlins/cheers.gif" alt="" />


#957974 - 02/21/10 10:30 PM Re: engine rebuild [Re: blitz]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Didn't quite get it done yesterday but close, my garage was so cold I had to keep coming in the house to warm up. I am relaxing today, I'm to old to be a contortionist and I'm pretty sore, the starter kicked my <img src="/forums/images/graemlins/butwiggle.gif" alt="" />. I'll tinker with after work this week and have it going by the weekend.

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.

#957975 - 02/28/10 09:44 PM Re: engine rebuild [Re: Hydra747]  
DamKia  Offline

Kia Moderator
Joined: Feb 2003
Posts: 2,243
Gold Coast, Queensland, Austra...
Can we all keep this thread nice and relevant please? Axe and I don't want to have to cull idle chit-chat from this thread. May be easier to cull the person....


2002 Sporty , Ironman 2.5" spring, 2" body, 15 x 7 ROH wheels, K&N, 15 x 10.5 Simex Centipedes, Powerchip 91.

"Never argue with an idiot. They will bring you down to their level then beat you with experience!"

#957976 - 03/01/10 03:46 AM Re: engine rebuild [Re: DamKia]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
...

Last edited by DamKia; 05/13/10 03:56 AM.

#957977 - 03/01/10 07:50 AM Re: engine rebuild [Re: Hydra747]  
DamKia  Offline

Kia Moderator
Joined: Feb 2003
Posts: 2,243
Gold Coast, Queensland, Austra...
Because this is tech. Dennis will be posting anything relevant to engine rebuilds here.

This is where pics of our rigs go.


2002 Sporty , Ironman 2.5" spring, 2" body, 15 x 7 ROH wheels, K&N, 15 x 10.5 Simex Centipedes, Powerchip 91.

"Never argue with an idiot. They will bring you down to their level then beat you with experience!"

#957978 - 03/02/10 12:42 AM Re: engine rebuild [Re: DamKia]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
...

Last edited by DamKia; 05/13/10 03:57 AM.

#957979 - 03/06/10 12:08 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
It's ALIVE! I got it started today, after I primmed the fuel pump it fired right up. The HLAs are a little noisy but other than that it sounds good and runs smooth. The clutch is also out of addjustment so after I get that addjusted I will take it for a spin. I have S&R training the rest of the weekend so I should be able to update Monday after work.

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.

#957980 - 03/06/10 12:13 AM Re: engine rebuild [Re: DennisThompson]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
...

Last edited by DamKia; 05/13/10 03:57 AM.

#957981 - 03/06/10 03:28 AM Re: engine rebuild [Re: Hydra747]  
DamKia  Offline

Kia Moderator
Joined: Feb 2003
Posts: 2,243
Gold Coast, Queensland, Austra...
...and not so much chat <img src="/forums/images/graemlins/wink.gif" alt="" />


2002 Sporty , Ironman 2.5" spring, 2" body, 15 x 7 ROH wheels, K&N, 15 x 10.5 Simex Centipedes, Powerchip 91.

"Never argue with an idiot. They will bring you down to their level then beat you with experience!"

#957982 - 03/07/10 06:30 PM Re: engine rebuild [Re: Hydra747]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Ok, First, I did not ask for this to be a sticky, the moderators thought it had some good tech info. It made me feel good they thought it had good enough info. I used my cell phone camara to take the pics because it was handy at the time. I'm not going to take things apart to take better pics. I didn't put in all the info I could have because you should use a shop manual anyway. I just wanted to show how you can save money by building an engine yourself instead of paying high shop prices. If any of you are in the middle of a rebuild and have questions you can PM or email me and I will help where I can.
So for now you got what you got, I hope it's good enough for you.

Thanks, 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.

#957983 - 03/08/10 07:47 PM Re: engine rebuild [Re: DennisThompson]  
Hydra747  Offline
Roll Me Over
Joined: Jun 2006
Posts: 3,814
South Texas *
...

Last edited by DamKia; 05/13/10 03:58 AM.

#957984 - 03/08/10 11:43 PM Re: engine rebuild [Re: Hydra747]  
bombardj1  Offline
Rock Warrior
Joined: Aug 2006
Posts: 893
New Philadelphia, Ohio, USA
head bolt # 0K95510135
washer # 0F80110138

DOHC


2001 5sp. K&N stock filter 215/70/15
If your check engine light is on at least you know the light still works

#957985 - 03/13/10 06:43 PM Re: engine rebuild [Re: bombardj1]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Just a little update, I still haven't had a chance to drive very far because the clutch slave clyinder is bad. I accidently pushed the piston in to far and can get it to bleed out. I will put the new one in today. I don't know what I did to this engine but so far it is the smoothest it has ever been, even when new. I hope it continues to run like this. The HLAs quited down also. So far I am very happy with it.

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.

#957986 - 05/03/10 05:14 AM Re: engine rebuild [Re: DennisThompson]  
Everet  Offline
Body Damage is Cool
Joined: Aug 2006
Posts: 1,224
Silicon Valley, CA
Ok,
It's been a more than a month. How is it running? Is fuel consumption the same?
Besides smoother, more power?
Time for an update.

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.

#957987 - 05/04/10 04:40 AM Re: engine rebuild [Re: Everet]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I know this sounds sad but the farthest I have driven it is to the car wash to wash off the inch of dust it got sitting in the garage for over a year. I finished building my rear bumper and notice there is no way it will pass inspection so I am now waiting for mud flaps I ordered. I have been working to many hours (not complaining, the money's nice) and have not had much time to work on the Kia. After this week we are shutting down for 6 weeks for computer upgrades so the ot will be gone so I should be driving it soon. It did seem to have good power going to the car wash though.

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.

#957988 - 06/09/10 04:34 AM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
Final update, The Kia is back in service and the engine is running great. I had a CEL right off the bat, it turned out to be the O2 sensor plug come unpluged and I had a slight oil leak that I traced to the valve cover gasket. It has good power but should get better as the engine brakes in and the gas milage is down a bit but again sould get better. It stays cool and runs smooth, so far I am very happy with the engine.
Thanks for everyones input and I hope this thread will help some of you out when you have to decide, should I buy or 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.

#957989 - 02/26/11 08:34 PM Re: engine rebuild [Re: DennisThompson]  
DennisThompson  Offline
Body Damage is Cool
Joined: Mar 2002
Posts: 1,396
Utah
I have a little over 10,000 miles on the engine now, still runs great, mileage is about 24 MPGs with the ATs and 22 with the MTs (corected after calculating my tire size). I am still fighting a valve cover gasket leak so my advice is to stick with Kia gaskets, I can't remember what brand mine was but it leakes on the cam bearing humps.

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.

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