Kia Sorento: Piston and Connecting Rod Assembly

1
Assemble the piston and connecting rod.
1. The piston front mark and the connecting rod front mark must face the timing chain side of the engine.
2. Before pressing in the piston pin, apply a coat of engine oil to the outer surface of the piston pin and connecting rod.
  Caution
  - Be careful not to damage the piston pin during assembly.
  - When replacing the piston pin, check the outer diameter of the piston pin and the inner diameter of the connecting rod small end, as shown 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.)
3. Install a snap ring on one side of the piston pin hole, then insert the piston pin into the piston pin hole and the connecting rod small end hole, aligning the front mark of the connecting rod and the piston.
  CautionBe careful not to damage or scratch the connecting rod small end hole, piston pin hole, and piston pin when installing the piston pin.
  
  NOTEAssembly condition: Temperature of piston, connecting rod and pin should be normal room temperature, 70 to 80 °C.
4. After inserting the piston pin, install the snap ring on the other side.
  CautionInstall the snap ring so that it fully seats in the piston pin hole groove. The snap ring must not be deformed during installation. Use a special service tool if necessary.
2
Install the piston rings.
1. Install the oil control ring with the coil spring by hand.
2. Using a piston ring expander, install the 2 compression rings with the code mark facing up.
3. Position the piston rings so that the ring end gaps are as shown in the illustration.
3
Install the connecting rod bearings.
1. Align the bearing tab with the groove in the connecting rod or connecting rod cap.
2. Install the bearings (A) in the connecting rod and connecting rod cap (B).
4
Remove the crankshaft. (Refer to Cylinder Block - Crankshaft)
5
Install the piston and connecting rod assembly.
NOTEBefore installing the pistons, apply engine oil to the piston ring grooves and cylinder bores.
1. Remove the connecting rod caps and install short pieces of rubber hose on the threaded ends of the connecting rod bolts.
2. Install the piston ring compressor, check that the bearings are seated correctly in place, then insert the piston into the cylinder and tap it in with the wooden handle of a hammer.
3. Stop after the piston ring compressor is released, and check the connection. Check the alignment of the connecting rod with the crankpin before inserting the piston into position.
4. Apply engine oil to the bolt threads. Using SST (09221-4A000), install the connecting rod caps with bearings and tighten the bolts. Tightening torque: 17.7 ~ 22 N·m + 78 ~ 82°
  NOTEAlways use new connecting rod cap bolts. Connecting rod cap bolts are torque-to-yield bolts designed to be permanently stretched beyond the elastic limit when tightened. If the bolts are removed and reused, they may break or fail to hold the clamping force.
  
  NOTEApply downward pressure on the piston ring compressor to prevent the rings from expanding before entering the cylinder bore.

Piston and Connecting Rod Assembly

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