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Home >> Kia >> 2004 >> Sorento EX, 4WD, Part Time >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 3.5L Engine >> Cylinder Block >> Piston And Connecting Rod >> Repair Procedures >> Reassembly

Repair Procedures: Reassembly

  1. Install the expander.
    Fig 1: Oil Ring Components
    G00340203Courtesy of KIA MOTORS AMERICA, INC.
    Fig 2: Aligning Oil Ring Spacer & Side Rail Gaps
    G00340204Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the upper side rail. To install the side rail, first put one end of the side rail between the piston ring groove and spacer, hold it firmly, and press down with finger on the portion to be inserted into the groove (as illustrated).
    CAUTION: Do not use a piston ring expander when installing the side rail.
  3. Install the lower side rail by the same procedure described in Step 2.
    Fig 3: Proper Technique To Install Side Rails
    G00340205Courtesy of KIA MOTORS AMERICA, INC.
  4. Apply engine oil around the piston and piston grooves.
  5. Using a piston ring expander, install the No. 2 piston ring.
  6. Install the No. 1 piston ring.
    Fig 4: Identifying No. 1 & 2 Piston Rings
    G00340206Courtesy of KIA MOTORS AMERICA, INC.
  7. Position each piston ring end gap as far away from its neighboring gaps as possible. Make sure that the gaps are not positioned in the thrust and pin directions.
  8. Hold the piston rings firmly with a piston ring compressor as they are inserted into cylinder.
    Fig 5: Aligning Piston Rings Gaps
    G00340207Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the upper connecting rod bearings in the connecting rod.
  10. Install the lower connecting rod bearing in the connecting rod bearing caps.
  11. Make sure that the front mark of the piston and the front mark (identification mark) of the connecting rod are directed toward the front of the engine.
  12. When the connecting rod cap is installed, make sure that any cylinder numbers placed on the rod and cap at disassembly match.
  13. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
  14. When assembling, bolts should be fastened using the plastic angle technique as follows.
    1. Apply oil to the threads and matching areas.
    2. Tighten the connecting rod bolt.

      Tightening torque 

      Connecting rod bolt:

      35 N.m + 92° (350 kg. cm + 92°, 26 lb. ft + 92°)

      CAUTION: After removing the connecting rod bolt, do not use it again.
      When using a new bolt, do not tighten the bolt more than 3 times.
      Fig 6: Connecting Rod Notches
      G00340202Courtesy of KIA MOTORS AMERICA, INC.
  15. Check the connecting rod side clearance.

    Connecting rod side clearance

    Standard: 0.10-0.25 mm (0.0039-0.0098 In.)

    Limit : 0.4 mm (0.0157 In.)

Fig 7: Measuring Connecting Rod Side Clearance
G00340209Courtesy of KIA MOTORS AMERICA, INC.
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