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Home >> Kia >> 2004 >> Sedona EX >> Repair and Diagnosis >> Engine Mechanical >> Timing Belt >> 3.5L Engine >> Engine Block Components >> Engine Block Reassembly >> Connecting Rod & Pistons
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Connecting Rod & Pistons

  1. Install the expander.
    Fig 1: Installing Expander
    G00320559Courtesy 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.
    Fig 2: Installing Upper Side Rail
    G00320560Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the lower side rail by the same procedure described in Step 2.
    Fig 3: Installing Lower Side Rail
    G00320561Courtesy 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: Installing No. 1 Piston Ring
    G00320562Courtesy 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: Holding Piston Rings With A Piston Ring Compressor
    G00320563Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the upper connecting rod bearings in the connecting rod.
  10. Install the lower connecting rod bearings 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 Nm + 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: Removing Connecting Rods
    G00320564Courtesy of KIA MOTORS AMERICA, INC.
  15. Check the bearing clearance as follows:
    1. Remove oil and dirt from the bearings and journals.
    2. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, avoiding the oil holes.
    3. Install the bearing and cap. Tighten to the specified torque. During this operation, do NOT turn the crankshaft.
    4. Remove the cap, measure at the widest part by using the scale printed on the plastigauge package.

      Connecting rod cap bearing clearance:

      Standard value:

      0.022-0.040 mm (0.0009-0.0016 in)

      Limit: 0.1 mm (0.0039 in)

    Fig 7: Checking Bearing Clearance
    G00320565Courtesy of KIA MOTORS AMERICA, INC.
  16. 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 8: Checking Connecting Rod Side Clearance
G00320566Courtesy of KIA MOTORS AMERICA, INC.
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