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Fi
g
. 1: General Specifications
Courtesy of KIA MOTORS AMERICA, INC.
Fig. 2: General Specifications
2002 Kia Sedona EX
2002 ENGINES 3.5L V6 - Sedona
Helpmelearn
June-06-08 8:54:28 AM
Page 2
© 2005 Mitchell Repair
Information Company, LLC.
1
3
Table of Contents
Main Page
3.5L V6-Sedona
1
General
1
Specifications
1
Torque Specifications
5
Cylinder Head Bolt Tightening Sequence
7
Intake Manifold Nut Tightening Sequence
8
Upper Oil Pan Bolt Tightening Sequence
9
Cylinder Head Cover Bolt Tightening Sequence
10
Lower Oil Pan Bolt Tightening Sequence
11
Antifreeze Service Standard
11
Antifreeze Coolant Chart
12
Sealant Chart
12
Special Service Tools
12
Checking Compression Pressure
13
Testing Compression
14
Checking Engine Oil
15
Selection of Engine Oil
15
Recommended Oil Viscosity Chart
16
Changing Engine Oil
17
Identifying Oil Drain Plug
17
Replacing Oil Filter
18
Illustrating Oil Filter
18
Illustrating Oil Pressure Switch
19
Removing & Installing Oil Pressure Switch
20
Drive Belt Routing
20
Power Steering Belt Routing
21
Air Conditioning Compressor & Alternator Belt Routing
22
Combined Drive Belt Routing
23
Drive Belt Adjustment
23
Power Steering
23
Alternator & Air Conditioning Compressor
23
Belt Adjustment
24
Adjusting Power Steering Belt Tension
25
Measuring Power Steering Belt Deflection
25
Adjusting Alternator & Air Conditioning Compressor Belt
26
Measuring Alternator & Air Conditioning Compressor Belt Deflection
27
Coolant Leak Check
27
Pressure Testing Radiator
28
Radiator Cap Pressure Test
28
Testing Radiator Cap
29
Specific Gravity Test
29
Cooling System Specifications
30
Testing Coolant Concentration & Specific Gravity
30
Engine Mounting
30
Identifying Engine Mounts
31
Identifying Subframe Mounts
32
Engine and Transaxle Assembly
32
Removal
32
Disconnecting the Speed Sensor Connector
34
Drain the Transaxle Oil
35
Removing Pinch Bolt from Knuckle
36
Removing the Drive Shaft from the Transaxle Housing
37
Support Auto Transaxle, Engine & Subframe with a Suitable Floor Jack
38
Timing System
38
Timing Belt
39
Identifying Timing System Components
39
Identifying Belt Routing
40
Removing the Upper & Lower Timing Belt Cover
41
Removing the Auto Tensioner
42
Remove the Timing Belt
43
Inspection
43
Testing Timing Belt for Vulcanization
44
Testing Timing Belt for Cracks
45
Testing Timing Belt for Side Face Wear
46
Testing Timing Belt for Abnormal Tooth Wear
47
Timing Belt Tensioner
47
Testing Timing Belt Tensioner
48
Identifying Timing Belt Positions
49
Timing Belt and Auto Tensioner
49
Installing the Idler Pulley to the Engine Support Lower Bracket
50
Installing the Tensioner Arm, Shaft and Plain Washer to the Cylinder Block
51
Installing the Crankshaft Sprocket
52
Align the Spacer & Pin
53
Installing & Aligning Camshaft Sprockets
54
Installing the Auto Tensioner to the Oil Pump Case
55
Identifying Timing Belt Routing
56
Exerting the Reverse-Directed Force to the Right Bank Exhaust Camshaft Sprocket
57
Adjusting Timing Belt Tension
57
Tensioning Timing Belt
58
Removing Auto Tensioner Fixing Pin
59
Measuring the Amount of Rod Protruding from Auto Tensioner
60
Exploded View of Camshaft Components
61
Removing Cylinder Head Cover
62
Removing Front Bearing Cover
63
Identifying Camshaft Components
64
Measuring Camshaft Wear
65
Rocker Arm
65
Leak down Test of Lash Adjuster
65
Releasing Air from Lash Adjuster
66
Measuring Lash Adjuster Drop
67
Adjustment of Rocker Arm Clearance
67
Measuring Rocker Arm Clearance
68
Installation
68
Camshaft and Bearing Cap
68
Installing Camshaft Dowel Pin
70
Camshaft Identification Signal
70
Illustrating Camshaft Inscribing Position
70
Illustrating Bearing Caps Identification Mark Chart
71
Illustrating Bearing Caps Identification Marks
71
Locating Bearing Cap Positions
72
Cylinder Head Assembly
72
Exploded View of Cylinder Head Assemblies
73
Disassembly
73
Removing Cylinder Head Bolt
73
Removing Retaining Lock
74
Compressing Valve Springs
74
Removing Valve Stem Seal
74
Removing Valve Stem Seals
75
Inspection & Servicing
75
Cylinder Head (Bare)
75
Measuring Cylinder Head Flatness
76
Valves
76
Illustrating Cleaning Valves
77
Valve Measurements
77
Illustrating Valve Margin
78
Valve Spring Height Measurements
79
Valve Spring Rectangularity Measurements
79
Measuring Valve Spring Values
79
Valve Guide Measurements
80
Measuring Valve Guide Clearance
80
Valve Seat Insert
80
Grinding Valve Seat
81
Valve Seat Angle Chart
82
Valve Seat Replacement Procedure
82
Insert Wall Removal Diagram
83
Valve Seat Specifications Chart
83
Valve Guide Replacement Procedure
83
Illustrating Valve Guide Installation Tool
84
Measuring Valve Guide Length
85
Valve Guide Insert Oversizes
85
Valve Guide Oversize Chart
86
Reassembly
86
Valve Stem Seal
86
Identifying Valve Stem Seal Position
87
Installing Valve Stem Seal
88
Valve Spring
88
Positioning Valve Spring
89
Retainer Lock
89
Installing Valve Retainer Lock
90
Cylinder Head Gasket
90
Illustrating Cylinder Head Gasket
91
Cylinder Head Bolt
91
Illustrating Cylinder Head Tightening Sequence
92
Lubrication System
92
Exploded View of Oil Pump & Oil Pan
93
Removing Oil Pressure Switch
94
Oil Pump Clearance
95
Illustrating Measuring Locations
95
Measuring Side & Body Clearance
96
Relief Plunger and Spring
96
Oil Filter Bracket
96
Oil Pressure Switch
96
Testing Oil Pressure Switch Continuity
97
Testing Oil Pressure Switch Continuity When Activated
98
Positioning Oil Pump Case & Gasket
99
Installing Oil Pump Seal
100
Installing Relief Plunger & Spring
101
Lower Oil Pan Tightening Sequence
103
Tightening Oil Pressure Switch
104
Main Moving System
104
Connecting Rod & Piston Assembly
104
Exploded View of Connecting Rod & Piston Assembly
105
Connecting Rod Cap
105
Marking Connecting Rod Assemblies
107
Piston Pin Removal & Installation
108
Illustrating Removal & Installation Tools
108
Piston Pin Removal Fixture
109
Piston Pin Installation Fixture
110
Illustrating Fixture Set-Up
111
Pistons and Piston Pins
112
Exploded View of Piston Rings
113
Piston Ring Mark & Limit
114
Connecting Rods
114
Positioning Connecting Rod Bearing
115
Positioning Oil Ring
116
Installing Oil Ring Side Rail
117
Installing Piston Rings
117
Positioning Piston Rings
118
Positioning Connecting Rod Bearing Cap
119
Measuring Bearing Clearance
120
Measuring Bearing Side Clearance
121
Crank Shaft
121
Exploded View of Crankshaft Components
122
Crankshaft Specification
123
Measuring Crankshaft Journal
124
Main Bearing and Connecting Rod Bearing
124
Oil Clearance Measurement
124
Measuring Oil Clearance
125
Plastigauge Method
125
Measuring Oil Clearance Using Plastigauge
126
Oil Seal
126
Driving Plate
126
Identifying Main Bearings
127
Crankshaft Bearing Cap Tightening Sequence
128
Measuring Crankshaft End Play
129
Positioning Rear Oil Seal Onto Special Tool
130
Installing Drive & Adapter Plates
131
Engine Block
131
Identifying Cylinder Block Components
132
Inspecting Cylinder Block
132
Measuring Cylinder Bore
133
Measuring Cylinder Block Flatness
135
Boring Cylinder
135
Piston Mark & Limit
135
Measuring Piston Diameter
136
Cooling System
137
Inlet Control
137
Illustrating Coolant Inlet Flow
137
Flow Chart
137
Illustrating Coolant Flow Chart
138
Radiator
138
Locating Radiator Components
139
Illustrating Radiator Cap Components
140
Inspecting Radiator Cap
141
Radiator Fan Motor
142
Exploded View of Fan Motor Assembly
143
Testing Radiator Fan Motor
144
Engine Water Pump
144
Exploded View of Water Pump Assembly
145
Water Pump Tightening Sequence
146
Exploded View of Thermostat Components
147
Testing Thermostat
148
Positioning Thermostat
149
Engine Water Hose/Pipes
150
Exploded View of Water Hoses
151
Water Temperature Gauge Unit and Sensor
151
Locating Water Temp Gauge Unit
152
Engine Coolant Hose/Pipes
152
Temperature Gauge Resistance Chart
153
Temperature Sender Resistance Chart
153
Testing Sending Unit
154
Positioning Water Pipe O-Ring
155
Sealant & Tightening Chart
156
Air Cleaner
156
Identifying Air Cleaner Components
157
Locating AFS Connector
158
Cleaning Air Cleaner
159
Surge Tank & Intake Manifold
159
Exploded View of Surge Tank & Intake Manifold
160
Disconnecting PCV Hose
161
Removing the Surge Tank Stay
162
Disconnecting High Pressure Fuel Hose
163
Removing the Surge Tank
164
Removing Surge Tank Gasket
165
Disconnecting Fuel Injector Harness Connector
166
Removing Fuel Delivery Pipe
167
Disconnecting Wiring Harness
168
Measuring Surge Tank Flatness
169
Illustrating Intake Manifold
170
Installing Surge Tank Stay
171
Exhaust System
172
Exhaust Manifold
172
Exploded View of Exhaust Manifold
172
Removing Heat Protector
173
Removing Exhaust Manifold
174
Exhaust Manifold Flatness Specifications
175
Measuring Exhaust Manifold Flatness
175
Installing Exhaust Manifold
176
Installing Heat Protector
177
Muffler
177
Identifying Muffler Components
178
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