Kia Sorento: Piston and Connecting Rod Inspection - Cylinder Block - Engine Mechanical System - Kia Sorento XM 2011-2023 Service ManualKia Sorento: Piston and Connecting Rod Inspection

Second Generation XM (2011-2023) / Kia Sorento XM 2011-2023 Service Manual / Engine Mechanical System / Cylinder Block / Piston and Connecting Rod Inspection

Connecting Rod

Check the connecting rod end play.
Using a feeler gauge, measure the end play while moving the connecting rod back and forth.

End play :
Standard : 0.10~ 0.25 mm (0.0039 ~ 0.0098 in.)
Limit : 0.35 mm (0.0138 in.)

If out-of-tolerance, install a new connecting rod.
If still out-of-tolerance, replace the crankshaft.
Check the connecting road bearing oil clearance.
Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
Remove 2 connecting rod cap bolts.
Remove the connecting rod cap and bearing half.
Clean the crank pin and bearing.
Place plastigage across the crank pin.
Reinstall the bearing half and cap, and torque the bolts.

Tightening torque
17.7~21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft) + 78 ~ 82°

Do not turn the crankshaft.
Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
Remove 2 bolts, connecting rod cap and bearing half.
Measure the plastigage at its widest point.

Standard oil clearance :
0.033 ~ 0.051 mm (0.00130 ~ 0.00201 in.)

If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
Do not file, shim, or scrape the bearings or the caps to adjust clearance.
If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
Connecting Rod Identification Mark

Connecting Rod Specifications
Inside Diameter
51.000 ~ 51.006 mm
(2.00787 ~ 2.00811 in.)
51.006 ~ 51.012 mm
(2.00811 ~ 2.00834 in.)
51.012 ~ 51.018 mm
(2.00834 ~ 2.00858 in.)

Piston And Rings

Clean piston
Using a gasket scraper, remove the carbon from the piston top.
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
The standard measurement of the piston outside diameter is taken 17 mm (0.67 in.) from the top land of the piston.

Standard diameter :
87.970 ~ 88.000 mm (3.46338 ~ 3.46456 in.)

Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance :
0.020 ~ 0.040 mm (0.00079 ~ 0.00157 in.)

Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance
No.1 : 0.050 ~ 0.080 mm (0.00197 ~ 0.00315 in.)
No.2 : 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
Oil ring : 0.020 ~ 0.055 mm (0.00079 ~ 0.00217 in.)
No.1 : 0.100 mm (0.00394 in.)
No.2 : 0.100 mm (0.00394 in.)
Oil ring : 0.60 mm (0.0236 in.)

If the clearance is greater than maximum, replace the piston.
Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter against the wear limits, If the bore is over the service limit, the cylinder block must be replaced.

Piston ring end gap
No.1 : 0.15 ~ 0.25 mm (0.0059 ~ 0.0098 in.)
No.2 : 0.37 ~ 0.47 mm (0.0145 ~ 0.0185 in.)
Oil ring : 0.20 ~ 0.50 mm (0.0079 ~ 0.0197 in.)
No.1 : 0.60 mm (0.0236 in.)
No.2 : 0.70 mm (0.0275 in.)
Oil ring : 0.80 mm (0.0315 in.)

Piston Pins

Measure the diameter of the piston pin.

Piston pin diameter :
21.997 ~ 22.000 mm (0.86602 ~ 0.86614 in.)

Measure the piston pin-to-piston clearance.

Piston pin-to-piston clearance :
0.003 ~ 0.010 mm (0.00012 ~ 0.00039 in.)

Check the difference between the piston pin diameter and the connecting rod bushing oil clearance.

Piston pin-to-connecting rod interference :
0.005 ~ 0.014 mm (0.00020 ~ 0.00055 in.)

Piston and Connecting Rod Disassembly
   • Use fender covers to avoid damaging painted surfaces. • ...

Piston and Connecting Rod Reassembly
   • Thoroughly clean all parts to be assembled. • ...

See also:

Circuit Diagram

Driver Airbag (DAB) Module and Clock Spring Inspection
Driver Airbag (DAB) If any improper parts are found during the following inspection, replace the airbag module with a new one.    ...

Component Replacement After Deployment
   Before doing any SRS repairs, use the GDS Pro to check for DTCs. Refer to the Diagnostic Trouble Code list for repairing ...

Copyright © 2014-2023