How LPG can destroy a 2.5L Carnival

[razzledog]

Well if it goes, it should be tomorrow...sometime before lunch, provided I get the electricals sorted and the manifold back on. Made my own stainless steel water pump inlet pipe as Kia were out of stock and the Rover one was too short.

[Conglomerate]

Good luck

Yes, Kia improved the K5 top cylinder heads and air intake chamber.
By all accounts an improvement upon the Rover design. (I like it)
hence the cam belts etc not fitting.

Applying a bead around bottom of sleeves whilst not a waste of time,
don't be surprised if you still get coolant leaking past.
The hylomar actually seals against the wall of the block, as it slides in.
the bead at lower lip is just excess thats pushed out from this sleeve/block wall interface.
Generally if the sleeve is loose - pull it & reseal.
Its should be really tight to slide in a hylomar sleeve.
You actually need to warm the block usually to get it moving...
But if the coolant showing in oil is only slight, more likely to be leaking thru a cooked metal layer gasket...
And Bars leak not much good for that pounding cycling...

Otherwise running engine with some bars leak initially will quite often seal it up.
Another reason to run engine initially in very low torque modes...
Add Bars leak to top radiator hose pipe before sealing hoses up with clamps.
Don't add to radiator cap or thermostat locations...

My other suggestion is to run the engine up to operating temperature
(fans will kick in) Do not drive around at all.
Then switch off and let engine cool.
Do this a couple of times - topping up coolant and observing everything like noise/leaks.
Don't be surprised if you see some white smoke coming off engine as it first hits operating temp. You usually have a bit of oil & stuff on the block that cooks off.
- So long as its not localized to one spot.

Doing this will help that piston bed in & align with the sleeve.
I generally replace sleeve & piston together.
But the cost of 'em now - its hardly worthwhile doing any longer.
Just get the new parts engine - better value long run.

I really think you are going to have problems with your heads if
the engine overheated. Check engine head bolt tension on easily accessible Left bank after about 1500km.


And go easy with your starter motor.
They are only light weight units and overheat quite quickly.
Short starts with key turned off in between will often start an engine when a long sustained ignition turn over is a waste of time.
You will have an initial compression problem until the piston ring seats with oil...

[PeterBlue]

Good luck (photo nearly had me choke on my weetbix though )

[razzledog]

Well the moment of truth came this afternoon...time to turn the key. Apart from an annoying coolant leak from the stupid plastic thermostat housing it seemed to run fine.
LPG is turned off..thought I'd see how it ran on petrol. It surprised me...

Kia Startup - YouTube

Kia Startup - YouTube

Thermo fan runs all the time..not sure why.

[PeterBlue]

Well done! first piston up!

[razzledog]

Well after an initial running, I went for a twenty kilometer drive and was quite surprised by how sweet this motor is. It's very gutsy, responsive and amazingly quiet. At idle I could balance a pencil on it....Haven't taken it above 2500 RPM and possibly will never need to pass the 3000 RPM mark! No oil/coolant leaks yet and it looks like the stainless steel water pump inlet pipe I made might hold...why Kia/Rover ever considered plastic as a material for these parts is a mystery.

Thermo fan has decided to function correctly now too...cutting in when the temp gauge reaches just under the halfway mark. The air con is wonderul and the Clarion wireless sounds like the Royal Albert Hall. This Carnival is pure pleasure to drive, just hope it all hangs together... after a few hundred more kilometers I'll report back.

Think I'll buy another blown up 2.5L...now I know what's inside.

[Wry 'Cuda]

Originally Posted by razzledog

Why Kia/Rover ever considered plastic as a material for these parts is a mystery.

Engine compartment is no place for (ordinary) plastic. Some time ago in Australia, there was a car with with UK genes that had a PLASTIC air-cleaner. Warped in quick time and let grit into the engine. Many new engines fitted under warranty.

[razzledog]

What's really scary.... the fuel rails are also made of plastic...

[matthew05]

hi razzledog, sent you a pm. got a 2004 carnival that's overheating, coolant suddenly disappeared.

[razzledog]

Filled the tank with LPG and threw the switch...motor runs fine on it, but I'll pick the time and place...only light loads, coolish weather and always start it on petrol.
It's hit the 1600k mark and still purring.