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

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

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
Assemble the piston and connecting rod.
The piston front mark and the connecting rod front mark must face the timing chain side of the engine.

Before pressing the piston pin, apply a coat of lubricant oil to the piston pin outer and connecting rod.
Take care that piston pin is not damaged during reassemble .
When replace the piston pin, check the piston pin outer diameter and connecting rod small end inner diameter as below.
Piston pin outer diameter : 21.997 ~ 22.000 mm (0.8660 ~ 0.8661 in)
Piston pin hole inner diameter : 22.003 ~ 22.007 mm (0.8662 ~ 0.8664 in)
Connecting rod small end inner diameter : 22.005 ~ 22.011 mm (0.8663 ~ 0.8665 in)
Interference : -0.014 ~ -0.005 mm (0.0006 ~ 0.0002 in)
Set the snap ring in one side of piston pin hole and insert the piston pin into the piston pin hole & the small end bore of connecting rod while meeting the front mark of connecting rod & piston.
Be sure to keep the small end bore, pistonpin hole & piston pin from being damaged and scratched when inserting the piston pin.
Assembling condition
Temperature : piston side 70 to 80C , connecting rod & pin is to be normal room temperature.
After inserting the piston pin, set the snap ring of the other side.
Set the snap ring so that it contacts completely with the groove of the piston pin hole.
The snap ring must not be deformed from the installation tooling method.
Install the piston rings .
Install the oil ring with coil spring by hand.
Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Position the piston rings so that the ring ends are as shown.

Install the connecting rod bearings.
Align the bearing claw with the groove of the connecting rod or connecting rod cap.
Install the bearings(A) in the connecting rod and connecting rod cap(B).

Remove the crankshaft.
(Refer to Cylinder Block - "Crandshaft")
Install piston and connecting rod assemblies.
Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts.
Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer.
Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place.
Apply engine oil to the bolt threads. Using the SST (09221-4A000), install the rod caps with bearings, 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°

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.
Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.

Piston and Connecting Rod Inspection
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