Kia 3.5L V6 - Exploded View of Connecting Rod & Piston Assembly; Connecting Rod Cap

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COMPONENTS

Fig. 106: Exploded View Of Connecting Rod & Piston Assembly

Courtesy of KIA MOTORS AMERICA, INC.

DISASSEMBLY

CONNECTING ROD CAP

2002 Kia Sedona EX

2002 ENGINES 3.5L V6 - Sedona

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3.5L V6-Sedona1
General1
Specifications1
Torque Specifications5
Cylinder Head Bolt Tightening Sequence7
Intake Manifold Nut Tightening Sequence8
Upper Oil Pan Bolt Tightening Sequence9
Cylinder Head Cover Bolt Tightening Sequence10
Lower Oil Pan Bolt Tightening Sequence11
Antifreeze Service Standard11
Antifreeze Coolant Chart12
Sealant Chart12
Special Service Tools12
Checking Compression Pressure13
Testing Compression14
Checking Engine Oil15
Selection of Engine Oil15
Recommended Oil Viscosity Chart16
Changing Engine Oil17
Identifying Oil Drain Plug17
Replacing Oil Filter18
Illustrating Oil Filter18
Illustrating Oil Pressure Switch19
Removing & Installing Oil Pressure Switch20
Drive Belt Routing20
Power Steering Belt Routing21
Air Conditioning Compressor & Alternator Belt Routing22
Combined Drive Belt Routing23
Drive Belt Adjustment23
Power Steering23
Alternator & Air Conditioning Compressor23
Belt Adjustment24
Adjusting Power Steering Belt Tension25
Measuring Power Steering Belt Deflection25
Adjusting Alternator & Air Conditioning Compressor Belt26
Measuring Alternator & Air Conditioning Compressor Belt Deflection27
Coolant Leak Check27
Pressure Testing Radiator28
Radiator Cap Pressure Test28
Testing Radiator Cap29
Specific Gravity Test29
Cooling System Specifications30
Testing Coolant Concentration & Specific Gravity30
Engine Mounting30
Identifying Engine Mounts31
Identifying Subframe Mounts32
Engine and Transaxle Assembly32
Removal32
Disconnecting the Speed Sensor Connector34
Drain the Transaxle Oil35
Removing Pinch Bolt from Knuckle36
Removing the Drive Shaft from the Transaxle Housing37
Support Auto Transaxle, Engine & Subframe with a Suitable Floor Jack38
Timing System38
Timing Belt39
Identifying Timing System Components39
Identifying Belt Routing40
Removing the Upper & Lower Timing Belt Cover41
Removing the Auto Tensioner42
Remove the Timing Belt43
Inspection43
Testing Timing Belt for Vulcanization44
Testing Timing Belt for Cracks45
Testing Timing Belt for Side Face Wear46
Testing Timing Belt for Abnormal Tooth Wear47
Timing Belt Tensioner47
Testing Timing Belt Tensioner48
Identifying Timing Belt Positions49
Timing Belt and Auto Tensioner49
Installing the Idler Pulley to the Engine Support Lower Bracket50
Installing the Tensioner Arm, Shaft and Plain Washer to the Cylinder Block51
Installing the Crankshaft Sprocket52
Align the Spacer & Pin53
Installing & Aligning Camshaft Sprockets54
Installing the Auto Tensioner to the Oil Pump Case55
Identifying Timing Belt Routing56
Exerting the Reverse-Directed Force to the Right Bank Exhaust Camshaft Sprocket57
Adjusting Timing Belt Tension57
Tensioning Timing Belt58
Removing Auto Tensioner Fixing Pin59
Measuring the Amount of Rod Protruding from Auto Tensioner60
Exploded View of Camshaft Components61
Removing Cylinder Head Cover62
Removing Front Bearing Cover63
Identifying Camshaft Components64
Measuring Camshaft Wear65
Rocker Arm65
Leak down Test of Lash Adjuster65
Releasing Air from Lash Adjuster66
Measuring Lash Adjuster Drop67
Adjustment of Rocker Arm Clearance67
Measuring Rocker Arm Clearance68
Installation68
Camshaft and Bearing Cap68
Installing Camshaft Dowel Pin70
Camshaft Identification Signal70
Illustrating Camshaft Inscribing Position70
Illustrating Bearing Caps Identification Mark Chart71
Illustrating Bearing Caps Identification Marks71
Locating Bearing Cap Positions72
Cylinder Head Assembly72
Exploded View of Cylinder Head Assemblies73
Disassembly73
Removing Cylinder Head Bolt73
Removing Retaining Lock74
Compressing Valve Springs74
Removing Valve Stem Seal74
Removing Valve Stem Seals75
Inspection & Servicing75
Cylinder Head (Bare)75
Measuring Cylinder Head Flatness76
Valves76
Illustrating Cleaning Valves77
Valve Measurements77
Illustrating Valve Margin78
Valve Spring Height Measurements79
Valve Spring Rectangularity Measurements79
Measuring Valve Spring Values79
Valve Guide Measurements80
Measuring Valve Guide Clearance80
Valve Seat Insert80
Grinding Valve Seat81
Valve Seat Angle Chart82
Valve Seat Replacement Procedure82
Insert Wall Removal Diagram83
Valve Seat Specifications Chart83
Valve Guide Replacement Procedure83
Illustrating Valve Guide Installation Tool84
Measuring Valve Guide Length85
Valve Guide Insert Oversizes85
Valve Guide Oversize Chart86
Reassembly86
Valve Stem Seal86
Identifying Valve Stem Seal Position87
Installing Valve Stem Seal88
Valve Spring88
Positioning Valve Spring89
Retainer Lock89
Installing Valve Retainer Lock90
Cylinder Head Gasket90
Illustrating Cylinder Head Gasket91
Cylinder Head Bolt91
Illustrating Cylinder Head Tightening Sequence92
Lubrication System92
Exploded View of Oil Pump & Oil Pan93
Removing Oil Pressure Switch94
Oil Pump Clearance95
Illustrating Measuring Locations95
Measuring Side & Body Clearance96
Relief Plunger and Spring96
Oil Filter Bracket96
Oil Pressure Switch96
Testing Oil Pressure Switch Continuity97
Testing Oil Pressure Switch Continuity When Activated98
Positioning Oil Pump Case & Gasket99
Installing Oil Pump Seal100
Installing Relief Plunger & Spring101
Lower Oil Pan Tightening Sequence103
Tightening Oil Pressure Switch104
Main Moving System104
Connecting Rod & Piston Assembly104
Exploded View of Connecting Rod & Piston Assembly105
Connecting Rod Cap105
Marking Connecting Rod Assemblies107
Piston Pin Removal & Installation108
Illustrating Removal & Installation Tools108
Piston Pin Removal Fixture109
Piston Pin Installation Fixture110
Illustrating Fixture Set-Up111
Pistons and Piston Pins112
Exploded View of Piston Rings113
Piston Ring Mark & Limit114
Connecting Rods114
Positioning Connecting Rod Bearing115
Positioning Oil Ring116
Installing Oil Ring Side Rail117
Installing Piston Rings117
Positioning Piston Rings118
Positioning Connecting Rod Bearing Cap119
Measuring Bearing Clearance120
Measuring Bearing Side Clearance121
Crank Shaft121
Exploded View of Crankshaft Components122
Crankshaft Specification123
Measuring Crankshaft Journal124
Main Bearing and Connecting Rod Bearing124
Oil Clearance Measurement124
Measuring Oil Clearance125
Plastigauge Method125
Measuring Oil Clearance Using Plastigauge126
Oil Seal126
Driving Plate126
Identifying Main Bearings127
Crankshaft Bearing Cap Tightening Sequence128
Measuring Crankshaft End Play129
Positioning Rear Oil Seal Onto Special Tool130
Installing Drive & Adapter Plates131
Engine Block131
Identifying Cylinder Block Components132
Inspecting Cylinder Block132
Measuring Cylinder Bore133
Measuring Cylinder Block Flatness135
Boring Cylinder135
Piston Mark & Limit135
Measuring Piston Diameter136
Cooling System137
Inlet Control137
Illustrating Coolant Inlet Flow137
Flow Chart137
Illustrating Coolant Flow Chart138
Radiator138
Locating Radiator Components139
Illustrating Radiator Cap Components140
Inspecting Radiator Cap141
Radiator Fan Motor142
Exploded View of Fan Motor Assembly143
Testing Radiator Fan Motor144
Engine Water Pump144
Exploded View of Water Pump Assembly145
Water Pump Tightening Sequence146
Exploded View of Thermostat Components147
Testing Thermostat148
Positioning Thermostat149
Engine Water Hose/Pipes150
Exploded View of Water Hoses151
Water Temperature Gauge Unit and Sensor151
Locating Water Temp Gauge Unit152
Engine Coolant Hose/Pipes152
Temperature Gauge Resistance Chart153
Temperature Sender Resistance Chart153
Testing Sending Unit154
Positioning Water Pipe O-Ring155
Sealant & Tightening Chart156
Air Cleaner156
Identifying Air Cleaner Components157
Locating AFS Connector158
Cleaning Air Cleaner159
Surge Tank & Intake Manifold159
Exploded View of Surge Tank & Intake Manifold160
Disconnecting PCV Hose161
Removing the Surge Tank Stay162
Disconnecting High Pressure Fuel Hose163
Removing the Surge Tank164
Removing Surge Tank Gasket165
Disconnecting Fuel Injector Harness Connector166
Removing Fuel Delivery Pipe167
Disconnecting Wiring Harness168
Measuring Surge Tank Flatness169
Illustrating Intake Manifold170
Installing Surge Tank Stay171
Exhaust System172
Exhaust Manifold172
Exploded View of Exhaust Manifold172
Removing Heat Protector173
Removing Exhaust Manifold174
Exhaust Manifold Flatness Specifications175
Measuring Exhaust Manifold Flatness175
Installing Exhaust Manifold176
Installing Heat Protector177
Muffler177
Identifying Muffler Components178

Kia 3.5L V6 - Exploded View of Connecting Rod & Piston Assembly; Connecting Rod Cap

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