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post #1 of 14 Old 04-17-2017, 10:12 PM Thread Starter
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Karlee the kia koup might have rod knock?!

This thread is going to be a documentary of Karlee's Engine Rebuild. I'll be taking pictures and we're looking into filming certain tasks.


BACKSTORY: There has been a slight knocking noise at a whisperingly low level around two-three months ago. The past weekend - it was extremely loud and knew for sure that something was suspect. (Might I add that my idiotic maneuver caused the violent loud knocking. While in motion, downshifted to 3rd from 4th at about 45 mph and proceeded to hit rev limiter for 2.5 - 3 seconds.)


Mileage: 94k
Oil Change: Every 3,000 miles
Oil Type: 5w-30 (I'm changing this in the future to 10w30)
Oil Filter: Mobil


Saturday, my friend and I got into the engine and disconnected pretty much everything (wiring harnesses, accessories, oil pan, downpipe, etc). This upcoming weekend, the engine will be coming out.


IMPORTANT NOTE: A hefty amount of metal shavings were found in the oil pan... Also, metal remnants were located in the oil pick-up...

If ya'll have any tips/suggestions, please let me know. I'm pretty active on the forums. WISH ME LUCK!

P.S. Plan A is to rebuild the engine. Plan B is to find a donor engine. I'm shootin' for Plan A.

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post #2 of 14 Old 04-17-2017, 10:25 PM Thread Starter
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While the engine is out, I'll be replacing a few items. First up on the list - new gaskets! I'm ordering Auto 7 gasket kit.


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File Type: jpg gasket_kit.jpg (55.0 KB, 8 views)

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post #3 of 14 Old 04-18-2017, 10:20 AM
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now is the time to stuff on a header and cat!
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post #4 of 14 Old 04-18-2017, 04:23 PM Thread Starter
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Originally Posted by bobozillamonster View Post
now is the time to stuff on a header and cat!
Definitely interested in upgraded that stuff! But, prioritizing my budget & build, my money will be going towards the engine rebuild first!

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post #5 of 14 Old 04-19-2017, 09:08 AM
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Good luck with the project!
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post #6 of 14 Old 04-19-2017, 03:59 PM Thread Starter
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THE START [1ST WEEKEND 16 APRIL 2017] PICS






Karlee is on two front jack stands.



Wiring harness has been fully disconnected.



"Nugget" is literally sitting in the engine bay unbolting the headers from the downpipe.



The valve cover is off.



TIME FOR THE 'MEAT AND POTATOES'


DAMAGES FOUND: pitting and worn down metal...



More damage found...



A sizeable amount of metal shavings found in the oil pan.





Let me know what you guys think of the damages found. That's a lot of metal shavings! And not to mention, more metal shavings were found in the oil pick up.


Stay tuned for next weekend!

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post #7 of 14 Old 04-19-2017, 06:18 PM
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Ouch, that's a lot of metal shavings. I'm not an auto mechanic, but I work on machines every day, and that amount of metal shavings would make me scream.

I'm curious though, you said the mileage is 94k, any reason this wasn't covered under warranty?
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post #8 of 14 Old 04-19-2017, 06:48 PM
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Quote:
Originally Posted by mechanizeddeath View Post
I'm curious though, you said the mileage is 94k, any reason this wasn't covered under warranty?
This story is kinda in 2 different threads. From this other thread: Engine knocking while on the gas with video

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Originally Posted by CaptainShanks View Post
Quote:
Originally Posted by kiaguy007 View Post
I'm assuming you didn't buy this Forte new, because you're not trying for 100K powertrain warranty coverage. So at what mileage did you buy it, and did you get any history of the earlier oil changes? Do you remember how the old oil looked when you did your first change?
I bought this Koup at 55k. As for history, I have no clue. Since I've had it, I've been keeping track of every maintenance tasks to include minor cosmetic changes, etc.

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post #9 of 14 Old 04-19-2017, 11:17 PM
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This story is kinda in 2 different threads. From this other thread: Engine knocking while on the gas with video
Oh, I gotcha. I keep forgetting that the 100k doesn't transfer to the 2nd owner. Bummer.

Hopefully it isn't too much work and cost to get it back on the road. Any rough estimate on how much you're in so far? (Assuming you feel like sharing this information, of course!)
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post #10 of 14 Old 04-20-2017, 08:07 AM
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Yeah, it stinks the 10y/100,000m warranty doesn't transfer. It really should. It's almost as if Hyu/Kia is banking that most people sell/trade-in the car before any problem happens that would normally be covered. Sucks for 2nd owners unless you buy a Hyu/Kia Certified car where the warranty does transfer.
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post #11 of 14 Old 04-26-2017, 08:01 PM Thread Starter
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Quote:
Originally Posted by mechanizeddeath View Post
Oh, I gotcha. I keep forgetting that the 100k doesn't transfer to the 2nd owner. Bummer.

Hopefully it isn't too much work and cost to get it back on the road. Any rough estimate on how much you're in so far? (Assuming you feel like sharing this information, of course!)
So far, my only purchase has been specialty tools... ~$75 I had to buy torque bits but the set I bought didn't have one large enough. So, I bought a separate T-60 and T-65 bit. Also, triple square spline bits were need. I bought a set, BUT, the two head bolts near the timing cover has a tight tolerance where a normal 3/8 inch triple spline bit would fit... So, I ordered extended triple spline bits. That's it so far!

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post #12 of 14 Old 04-26-2017, 08:03 PM Thread Starter
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Quote:
Originally Posted by CaptainShanks View Post
So far, my only purchase has been specialty tools... ~$75 I had to buy torque bits but the set I bought didn't have one large enough. So, I bought a separate T-60 and T-65 bit. Also, triple square spline bits were need. I bought a set, BUT, the two head bolts near the timing cover has a tight tolerance where a normal 3/8 inch triple spline bit would fit... So, I ordered extended triple spline bits. That's it so far!





This is what we need and what I ordered.

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Last edited by CaptainShanks; 04-26-2017 at 08:51 PM. Reason: added new pic
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post #13 of 14 Old 04-26-2017, 08:47 PM Thread Starter
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Weekend 2 - Pullin' the motor!

Weekend 2 [22-23 April 2017] Pullin' the motor!


We definitely encountered minor set backs. But, all three of us being crew chiefs on F-35's, we utilized our training and ingenuity to overcome the small problems. The engine is currently on an engine stand, not fully apart because of two, constricted head bolts near the timing chain side. We found a couple of things, but so far, nothing too concerning.


We pulled the control arms, drive shaft, & brake assemblies off. Karlee is literally sittin' on junk Miata wheels. We did this to lower the vehicle so we could get clearance for the engine hoist.




The engine hoist is attached. The seatbelt we engineered was too long to clear the garage.



Here's a time-lapse of the engine pull. Sorry in advanced for the potato quality. Feel free to ask questions!
https://youtu.be/orG7JSZpATw


We shortened the seat belt, lowered the car off the jack stands and onto Miata tires, and Viola! The engine is pulled!



Here's the empty engine bay.



The bell-housing disconnected from the transaxle.




Pics of the pressure plate and flywheel.




Here, you can see that the timing cover is removed.



This is where we stopped on Saturday night. The electric impact wrench that my buddy had didn't have enough power... Somehow, we managed to get ONE flywheel bolt off. I also had to purchase this specific size torque bit. It's either T-60 or T-65.



SUNDAY
Our goal for today was to remove the remaining flywheel bolts & mount the engine on a stand. We borrowed an air compressor and air impact wrench from a friend. Within ten seconds, all fly wheel bolts were removed. PRO TIP: having an air compressor with an air impact wrench helps tremendously!


Now that the flywheel is off, we can finally mount it on the engine stand.



The valve caps fell out as we turned the engine upside down to inspect and remove the oil pump.

There are some metal shavings near the top of this oil pump.



The bottom end. Here you can see cylinder 2 and 3 has some burnt discoloration.

We inspected what we could see from this angle. The wrist pins, the rods, the cylinder walls, the underside of the pistons didn't seem too damaged.

This was our stopping point for Sunday evening. We couldn't really press on until we get the head off (see above post for reason why).


This upcoming weekend, I'm wanting to get the head off to finally see what the exact damage could be. Since my buddies are so graciously helping me, I'll be helping them this weekend. We have a jet ski engine rebuild to do and the start of a dirtbike rebuild.


Comment on what you think about the discrepancies that we found.


STAY TUNED FOR NEXT WEEKEND!

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post #14 of 14 Old 04-27-2017, 12:29 AM
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Awesome! Glad to see this has a nice guide on what you're doing.

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