Kia 3.5L V6 Manual Download Page 164

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Fig. 162: Removing The Surge Tank

Courtesy of KIA MOTORS AMERICA, INC.

6. After removing the surge tank, remove the gasket.

2002 Kia Sedona EX

2002 ENGINES 3.5L V6 - Sedona

Helpmelearn

June-06-08 8:54:33 AM

Page 164

Summary of Contents for 3.5L V6

Page 1: ...a Sedona EX 2002 ENGINES 3 5L V6 Sedona 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 1 2005 Mitchell Repair Information Company LLC Helpmelearn June 06 08 8 54...

Page 2: ...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...

Page 3: ...MOTORS AMERICA INC Fig 3 General Specifications Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 3 2005 Mitchell Repair Informat...

Page 4: ...eral Specifications Courtesy of KIA MOTORS AMERICA INC TORQUE SPECIFICATIONS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 4 2005 Mitchell Repair Information Co...

Page 5: ...15 22 M10 24 37 33 50 Engine Coolant Temperature Sensor Gauge Unit Bolt 15 30 20 40 Engine Hanger Bracket Bolt 20 26 27 35 Exhaust Manifold Nut 20 24 27 32 Front Exhaust Pipe To Converter Bolt 30 44...

Page 6: ...Support Bracket Bolt 89 133 10 15 Oil Filter 106 142 12 16 Oil Level Gauge Guide To Engine Bolt 106 133 12 15 Oil Pressure Switch 71 106 8 12 Oil Pump Case Bolts 106 133 12 15 Oil Pump Cover Screw 71...

Page 7: ...ylinder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 7 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 7 2005 Mitchell Repair Information Comp...

Page 8: ...ntake Manifold Nut Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 8 2005 Mitchell Repair Information Compa...

Page 9: ...Upper Oil Pan Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 9 2005 Mitchell Repair Information Compa...

Page 10: ...nder Head Cover Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 28 AM Page 10 2005 Mitchell Repair Information Co...

Page 11: ...OTORS AMERICA INC FLUIDS ANTIFREEZE SERVICE STANDARD Fig 10 Antifreeze Service Standard Chart Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8...

Page 12: ...SEALANT Fig 12 Sealant Chart Courtesy of KIA MOTORS AMERICA INC SPECIAL SERVICE TOOLS Fig 13 Special Service Tools Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona He...

Page 13: ...l and that the starter motor and battery are all in normal operating condition 2 Start the engine and wait until engine coolant temperature has risen to 80 95 C 3 Stop the engine and disconnect the sp...

Page 14: ...ue 1 200 kPa 12 2 kg cm2 170 psi Limit 1 050 kPa 10 7 kg cm2 149 psi Fig 15 Testing Compression Courtesy of KIA MOTORS AMERICA INC 9 Repeat steps 6 through 8 on all cylinders making sure ensuring that...

Page 15: ...ion vehicle on a level surface 2 Stop the engine 3 If the oil is found to have fallen to the lower limit the L mark refill to the F mark 4 Check that the oil is not dirty or mixed with coolant or gaso...

Page 16: ...ch a Confirm to the requirements of the API classification b Have proper SAE grade number for expected ambient temperature range Lubricants which do not have both an SAE grade number and an API servic...

Page 17: ...o the specified torque 26 30 ft lbs 35 45 N m 5 Install oil filter 6 Fill the engine with new engine oil through the oil filling hole Amount of oil 4 5 qts 4 3Liters CAUTION Whenever tightening an oil...

Page 18: ...ters should be used to assure the most efficient service Make sure that the rubber gasket from the old filter is completely removed from the mating surfaces on the engine block before installing the n...

Page 19: ...is set to ON check switch lamp and wiring 2 If there is current flow when ignition switch is set to ON and if there is no current flow when engine is running at idle switch is good If switch is good...

Page 20: ...f KIA MOTORS AMERICA INC DRIVE BELT ROUTING 1 For power steering belt routing see Fig 21 2 For air conditioning compressor and alternator belt routing see Fig 22 3 For combined belt routing see Fig 23...

Page 21: ...g 21 Power Steering Belt Routing Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 21 2005 Mitchell Repair Information Company LL...

Page 22: ...ditioning Compressor Alternator Belt Routing Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 22 2005 Mitchell Repair Informatio...

Page 23: ...hinge bolt A and flange nut B to specification See TORQUE SPECIFICATIONS table Alternator Air Conditioning Compressor 1 Loosen pulley lock nut A See Fig 26 2 Turn adjustment bolt B to set belt tension...

Page 24: ...ation 1 Deflection In mm Alternator Air Conditioning Compressor New Belt Deflection 20 22 5 5 5 Used Belt Deflection 24 28 6 7 After Operation 31 8 Power Steering New Belt Deflection 35 43 9 11 Used B...

Page 25: ...rtesy of KIA MOTORS AMERICA INC Fig 25 Measuring Power Steering Belt Deflection Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page...

Page 26: ...g Alternator Air Conditioning Compressor Belt Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 26 2005 Mitchell Repair Informati...

Page 27: ...2 Confirm that the coolant level is up to the filler neck 3 Install a radiator cap tester to the radiator filler neck and apply 22 lbs of pressure Hold for two minutes in that condition while checking...

Page 28: ...e coolant could spray out causing personal injury Allow the vehicle to cool before servicing this system z Be sure to completely clean away any moisture from the places checked z When the tester is re...

Page 29: ...n at or above the limit SPECIFIC GRAVITY TEST 1 Measure the specific gravity of the coolant with a hydrometer 2 Measure the coolant temperature and calculate the concentration from the relation betwee...

Page 30: ...rty will be adversely affected If the concentration is above 60 percent both the antifreeze and engine cooling properties will decrease and may adversely affect the engine Fig 30 Testing Coolant Conce...

Page 31: ...entifying Engine Mounts Courtesy of KIA MOTORS AMERICA INC SUB FRAME MOUNTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 31 2005 Mitchell Repair Information Co...

Page 32: ...esy of KIA MOTORS AMERICA INC ENGINE AND TRANSAXLE ASSEMBLY REMOVAL 1 Remove the battery and engine cover 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 32 2005...

Page 33: ...in fuel line and the return and vapor hoses from the engine side 14 Disconnect the heater hose Intake and exhaust at the engine side 15 The accelerator cable should be removed from the engine side 16...

Page 34: ...RS AMERICA INC 19 Remove the power steering oil pump hose 20 Raise the vehicle 21 Remove the oil pan shield 22 Drain the transaxle oil 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 0...

Page 35: ...om steering knuckles 25 Remove control link from stabilizer and lower arm 26 Remove pinch bolt from knuckle Separate lower arm form knuckle NOTE Use a wire to suspend the exhaust pipe from the bottom...

Page 36: ...ansaxle housing CAUTION z Plug up the holes of the transaxle case to prevent entry of foreign material z The circlips on the drive shafts should be replaced whenever reinstalling 2002 Kia Sedona EX 20...

Page 37: ...NC 28 Remove intermediate shaft bolt See REMOVAL 29 Remove No 3 No 4 engine mounting 30 Support auto transaxle engine and subframe with a suitable floor jack 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Se...

Page 38: ...nd blots of impact bar and subframe 32 Slowly lower engine auto transaxle and subframe 33 Remove No 1 No 2 engine mounting from subframe 34 Separate auto transaxle from engine TIMING SYSTEM 2002 Kia S...

Page 39: ...AMERICA INC REMOVAL 1 Remove the engine cover 2 Remove the drive belt 3 Remove the idler pulley crankshaft pulley power steering pulley and tensioner pulley 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sed...

Page 40: ...Routing Courtesy of KIA MOTORS AMERICA INC 4 Remove the upper and lower timing belt cover 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 40 2005 Mitchell Repair...

Page 41: ...engine with garage jack or special tool and then remove the engine mounting insulator 6 Remove the auto tensioner CAUTION Take care not to deform the engine oil pan 2002 Kia Sedona EX 2002 ENGINES 3 5...

Page 42: ...lign the timing mark to get the No 1 cylinder s piston be in TDC position compression stroke At this time the timing marks of the camshaft sprocket and cylinder head cover should coincide with each ot...

Page 43: ...on of the rubber backside The backside is glossy and non elastic so that even if a finger nail is forced into it no mark is produced NOTE When re using timing belt make sure of marking the rotating di...

Page 44: ...lt For Vulcanization Courtesy of KIA MOTORS AMERICA INC 2 Crack on the rubber belt surface 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 44 2005 Mitchell Repair...

Page 45: ...OTORS AMERICA INC 3 Abnormal wearing of side face of belt CAUTION Belts in good condition seem to be cut by a sharp knife 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29...

Page 46: ...g Belt For Side Face Wear Courtesy of KIA MOTORS AMERICA INC 4 Abnormal tooth wearing 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 46 2005 Mitchell Repair Info...

Page 47: ...en and rough Last stage Fabric wearing of side face of load exerting tooth occurs and rubber is exposed Length between teeth decrease 5 Missing tooth TIMING BELT TENSIONER If any abnormal noise or dif...

Page 48: ...sting Timing Belt Tensioner Courtesy of KIA MOTORS AMERICA INC INSTALLATION 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM Page 48 2005 Mitchell Repair Information Co...

Page 49: ...KIA MOTORS AMERICA INC TIMING BELT AND AUTO TENSIONER 1 Install the idler pulley to the engine support lower bracket 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 29 AM P...

Page 50: ...MOTORS AMERICA INC 2 Install the tensioner arm shaft and plain washer to the cylinder block Tightening torque 35 55 N m 350 550 kg cm 25 82 40 57 lb ft 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona...

Page 51: ...he Cylinder Block Courtesy of KIA MOTORS AMERICA INC 3 Install the crankshaft sprocket NOTE Confirm if timing marks coincide with 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08...

Page 52: ...S AMERICA INC CAUTION Align the spacer with a pin and assemble it exerting even force not to deform the crankshaft sensing blade 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8...

Page 53: ...he Spacer Pin Courtesy of KIA MOTORS AMERICA INC 4 Install the camshaft sprocket 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 53 2005 Mitchell Repair Informati...

Page 54: ...er to the oil pump case CAUTION When installing camshaft sprocket tighten the bolt holding hexagonal part of camshaft to prevent it from turning CAUTION At this time the auto tensioner s set pin shoul...

Page 55: ...tension between each shaft in this order Crankshaft sprocket Idler pulley Left bank exhaust camshaft sprocket Left bank intake camshaft sprocket Water pump pulley Right bank intake camshaft sprocket R...

Page 56: ...be careful with the right bank z In case the right bank camshaft sprocket rotates excessively be cautious not to rotate more than the initial stable position Always align timing mark of rotating sproc...

Page 57: ...o tensioner set pin ADJUSTING TIMING BELT TENSION 1 Tension setting While auto tensioner is not operating And set pin being kept installed 1 After rotating crankshaft 1 4 revolution reversely rotate i...

Page 58: ...Center bolt standard torque 43 55 N m 430 550 kg cm 31 72 40 57 lb ft Fig 57 Tensioning Timing Belt Courtesy of KIA MOTORS AMERICA INC 2 Pull out the auto tensioner fixing pin 2002 Kia Sedona EX 2002...

Page 59: ...inder at TDC wait for about 5 minutes and measure the amount of protruding of the auto tensioner rod b Check if the amount of rod protruding is in the range of 3 8 4 5mm CAUTION This is leak down time...

Page 60: ...c Recheck if each sprocket is within the specified range CAMSHAFT COMPONENTS NOTE If it is not within the specified range repeat from TIMING BELT AND AUTO TENSIONER 2002 Kia Sedona EX 2002 ENGINES 3...

Page 61: ...shaft Components Courtesy of KIA MOTORS AMERICA INC REMOVAL 1 Remove the cylinder head cover 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 61 2005 Mitchell Repa...

Page 62: ...Fig 61 Removing Cylinder Head Cover 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 62 2005 Mitchell Repair Information Company LLC...

Page 63: ...IA MOTORS AMERICA INC 3 Remove the rear bearing cap 4 Remove the bearing cap 5 Remove the camshaft oil seal 6 Remove the camshaft 7 Remove the rocker arm 8 Remove the lash adjustor 2002 Kia Sedona EX...

Page 64: ...urnal or and cam lobe after checking replace it with a new one Measure the height of cam and if the readings are beyond the specification replace it Standard value Intake 35 198 mm 1 385 in Exhaust 34...

Page 65: ...the lash adjuster in light oil 2 Push out the steel ball in the lash adjuster softly using the special tool Air bleed wire 09246 32200 and CAUTION z As the lash adjuster is a precise part take care n...

Page 66: ...hen release air from plunger feels and test again If the plunger feels still soft even after releasing air replace it CAUTION As the ball weight is very small just a few grams pushing the special tool...

Page 67: ...C Fig 66 Measuring Lash Adjuster Drop Courtesy of KIA MOTORS AMERICA INC ADJUSTMENT OF ROCKER ARM CLEARANCE 1 Replace the rocker arm with the one specially made for measurement 2 After positioning th...

Page 68: ...rm Clearance Courtesy of KIA MOTORS AMERICA INC INSTALLATION CAMSHAFT AND BEARING CAP CAUTION As the ball weight is very small just a few grams pushing the special tool excessively can damage the lash...

Page 69: ...the position of the rocker arm whether it is exactly installed on the lash adjuster and valve or not 3 Install the camshaft dowel pin as shown 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelea...

Page 70: ...ing Camshaft Inscribing Position Courtesy of KIA MOTORS AMERICA INC 5 Confirm the identification mark and the number Bearing caps of No 3 No 4 and No 5 have the front mark and arrange the front mark u...

Page 71: ...ghten the bearing cap in two or three steps Tighten it to the standard torque at the last stage Bearing cap standard torque 16 pieces at the both ends 21 26 N m 210 260 kg cm 15 19 ft lbs 24 pieces in...

Page 72: ...ing Cap Positions Courtesy of KIA MOTORS AMERICA INC CYLINDER HEAD ASSEMBLY COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 72 2005 Mitchell Repair Inf...

Page 73: ...rrange removal parts according to cylinder numbers intake and exhaust valves REMOVING CYLINDER HEAD BOLT Remove the cylinder head bolts using the hexagonal wrench 2002 Kia Sedona EX 2002 ENGINES 3 5L...

Page 74: ...100 Fig 74 Compressing Valve Springs Courtesy of KIA MOTORS AMERICA INC 2 Remove the retainer lock REMOVING VALVE STEM SEAL Do not reuse the valve stem seal 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sed...

Page 75: ...assages are not clogged 2 Visually check the cylinder head for cracks damage or water leakage 3 Check the cylinder head gasket surface for flatness with a straight edge and feeler as shown in illustra...

Page 76: ...Head Flatness Courtesy of KIA MOTORS AMERICA INC VALVES 1 Clean the valve with wire brush 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 76 2005 Mitchell Repair...

Page 77: ...if there is wear replace the valve If margin is smaller than service standard replace the valve VALVE MEASUREMENTS Application Margin Standard In mm Margin Limit In mm Intake 0 039 1 0 0 02 0 5 Exhaus...

Page 78: ...ig 78 Illustrating Valve Margin Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 78 2005 Mitchell Repair Information Company LLC...

Page 79: ...REMENTS VALVE SPRING RECTANGULARITY MEASUREMENTS Fig 79 Measuring Valve Spring Values Application Margin Standard In mm Margin Limit In mm Height With No Load 1 8268 46 4 1 7874 45 4 Application Stand...

Page 80: ...ve guide If the guide is worn replace it and adjust the seat ring Adjust the valve seat with grinder or cutter making valve seat contact width from the center of valve face to within the specified val...

Page 81: ...Fig 81 Grinding Valve Seat Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 30 AM Page 81 2005 Mitchell Repair Information Company LLC...

Page 82: ...PROCEDURE 1 If the valve seat insert is excessively worn cut out the insert wall using valve seat cover at normal temperature See figure A in figure 83 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona...

Page 83: ...eat insert At this time the temperature of oversize seat insert must be the same as the room temperature When new valve seat is installed adjust the valve seat face For valve seat specifications see c...

Page 84: ...ls By using the valve guide installer it can be pressed in the specified height Fig 85 Illustrating Valve Guide Installation Tool Courtesy of KIA MOTORS AMERICA INC 4 Valve guide is to be installed fr...

Page 85: ...NC 5 When the valve guide is replaced inspect for valve contact state If necessary adjust the valve seat VALVE GUIDE INSERT OVERSIZES 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06...

Page 86: ...REASSEMBLY VALVE STEM SEAL 1 Install the valve spring seat 2 Install a new stem seal on valve guide using the special tool 09222 28200 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 0...

Page 87: ...Incorrect seal installation can cause oil leakage through lower part of the valve guide When the valve stem seal is removed due to missing of valve spring seat the stem seal cannot be reused 2002 Kia...

Page 88: ...INC VALVE SPRING Install the valve spring so that the end part with identification mark is paced at the end of the spring retainer 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08...

Page 89: ...RS AMERICA INC RETAINER LOCK Insert the retainer lock by pressing down the valve spring with special tool 09222 28000 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM P...

Page 90: ...t on the cylinder block and the cylinder head should be cleaned 2 Install new cylinder head gasket on the cylinder head assembly Do not smear the sealant on the gasket and only the new gasket must be...

Page 91: ...OLT 1 Tighten the cylinder head bolts as shown in illustration below using the appropriate tool Tightening torque 105 115 N m 1050 1150 kg cm 75 9 83 2 lb ft 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Se...

Page 92: ...er Head Tightening Sequence Courtesy of KIA MOTORS AMERICA INC LUBRICATION SYSTEM COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 92 2005 Mitchell Repa...

Page 93: ...n Courtesy of KIA MOTORS AMERICA INC DISASSEMBLY 1 Remove the oil pressure switch using 24 mm deep socket 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 93 2005...

Page 94: ...bolts and remove the oil filter bracket and gasket 5 Remove the oil relief valve plug from the oil pump case 6 Remove the oil pump case INSPECTION NOTE Since a sealant is used on the threaded area be...

Page 95: ...clearance with a thickness gauge OIL PUMP CLEARANCE Fig 96 Illustrating Measuring Locations Application Standard In mm Body Clearance 0 0039 0 0071 0 100 0 181 Side Clearance 0 0016 0 0037 0 040 0 095...

Page 96: ...or the deformed or broken condition OIL FILTER BRACKET 1 Make sure that there is no damage on the oil filter installation surface 2 Check the oil filter bracket for oil leaks or cracks OIL PRESSURE SW...

Page 97: ...KIA MOTORS AMERICA INC 2 Check the continuity between the terminal and the body when the fine wedge is pushed If there is continuity even when the fine wedge is pushed replace it 2002 Kia Sedona EX 20...

Page 98: ...oil hole the switch is operating properly Check that air doesn t leak If air leaks the diaphragm is broken replace it REASSEMBLY 1 Install the oil pump case with the gasket Tightening torque Oil pump...

Page 99: ...ioning Oil Pump Case Gasket Courtesy of KIA MOTORS AMERICA INC 2 Install the oil seal in the oil pump case using special tool 09214 33000 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn Jun...

Page 100: ...ger and spring and tighten the oil relief valve plug to the specified torque Tightening torque Oil relief valve plug 40 50 N m 400 500 kg cm 29 5 36 88 lb ft 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Se...

Page 101: ...lunger Spring Courtesy of KIA MOTORS AMERICA INC 4 Install the oil screen with a new gasket 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 101 2005 Mitchell Repa...

Page 102: ...bolt No 1 14 9 8 11 8 N m 100 120 kg cm 7 2 8 7 lb ft N m No 15 16 5 7 50 70 kg cm 3 68 5 16 lb ft Upper oil pan and transaxle mounting bolt 4EA 30 42 N m 300 420 kg cm 22 13 30 98 lb ft Fig 103 Upper...

Page 103: ...8 N m 100 120 kg cm 7 2 8 7 lb ft Fig 104 Lower Oil Pan Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 9 Using 24 mm deep socket install the oil pressure switch after applying sealant to the...

Page 104: ...Tightening Oil Pressure Switch Courtesy of KIA MOTORS AMERICA INC MAIN MOVING SYSTEM CONNECTING ROD PISTON ASSEMBLY NOTE Do not tighten the oil pressure switch to the excessive torque 2002 Kia Sedona...

Page 105: ...f Connecting Rod Piston Assembly Courtesy of KIA MOTORS AMERICA INC DISASSEMBLY CONNECTING ROD CAP 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 105 2005 Mitche...

Page 106: ...ston connecting rod assembly toward the top of the cylinder CAUTION Keep the bearings in order with their corresponding connecting rods according to cylinder numbers for proper reassembly 2002 Kia Sed...

Page 107: ...2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 107 2005 Mitchell Repair Information Company LLC...

Page 108: ...Removal Installation Tools Courtesy of KIA MOTORS AMERICA INC 2 Place the proper insert tool between the connecting rod and piston 3 Insert the proper removing tool through the hole CAUTION After remo...

Page 109: ...ting rod 5 Install proper pin guide through piston into connecting rod Hand tap pin guide into piston for proper retention Install piston pin into the other side of the piston 2002 Kia Sedona EX 2002...

Page 110: ...nters on the connecting rod in the piston When the piston connecting rod piston pin and pin guide assembly are positioned on the fork tool the guide pin will also center on the tool assembly If a pin...

Page 111: ...cified alphanumeric is obtained 8 Insert the installing tool through the hole in the arch of the tool Press the piston pin into the connecting rod until the sleeve in the installing arbor contacts the...

Page 112: ...STON RINGS 1 Measure the piston ring side clearance If the measured value exceeds the service limit insert a new ring in the ring groove the measure the side clearance If the clearance still exceeds t...

Page 113: ...112 Exploded View Of Piston Rings Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 113 2005 Mitchell Repair Information Company...

Page 114: ...the gap with the ring positioned at the lower part of the cylinder that is the less worn When replacing a ring be sure to the use a ring of the same size PISTON RING MARK LIMIT CONNECTING RODS 1 When...

Page 115: ...necting Rod Bearing Courtesy of KIA MOTORS AMERICA INC REASSEMBLY 1 Install the expander 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 31 AM Page 115 2005 Mitchell Repair...

Page 116: ...and spacer hold it firmly and press down with finger on the portion to be inserted into the groove See Fig 115 3 Install the lower side rail by the same procedure described above CAUTION Do not use a...

Page 117: ...nd piston grooves 5 Using a piston ring expander install the No 2 piston ring 6 Install the No 1 piston ring Fig 116 Installing Piston Rings Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002...

Page 118: ...he lower connecting rod bearings into the connecting rod bearing caps 11 Make sure that the front mark of the piston and the front mark identification mark of the connecting rod are directed toward th...

Page 119: ...ned using the following technique a Apply oil to the threads and matching areas b Tighten the connecting rod bolt Connecting rod bolt tightening torque 35 N m 92 350 kg cm 92 26 lb ft 92 2002 Kia Sedo...

Page 120: ...emove the cap measure at the widest part by using the scale printed on the plastigauge package Connecting rod cap bearing clearance standard value 0 022 0 040 mm 0 0009 0 0016 in Limit 0 1 mm 0 0039 i...

Page 121: ...10 0 25 mm 0 0039 0 0098 in Limit 0 4 mm 0 0157 in Fig 120 Measuring Bearing Side Clearance Courtesy of KIA MOTORS AMERICA INC CRANK SHAFT COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Hel...

Page 122: ...1 Remove the timing belt cylinder head assembly drive plate transaxle mounting plate oil pan See TIMING SYSTEM 2 Remove the oil seal case and the rear oil seal 2002 Kia Sedona EX 2002 ENGINES 3 5L V6...

Page 123: ...eck the oil holes for restrictions Repair or replace any defective part 2 Inspect for out of roundness and taper of the crankshaft journal and pin Fig 122 Crankshaft Specification Courtesy of KIA MOTO...

Page 124: ...ck for oil clearance by measuring the outside diameter of the crankshaft journal and the inside diameter of the bearing The clearance can be obtained by calculating the difference between the measured...

Page 125: ...o measure the clearance 1 Remove oil and grease and any other dirt from the bearings and journals 2 Cut the plastigauge to the same length as the width of the bearing and place it in parallel with the...

Page 126: ...hould be replaced or an undersize bearing should be used When installing a new crankshaft be sure to use standard size bearings Should the standard clearance not be obtained even after bearing replace...

Page 127: ...3 Install the crankshaft Apply engine oil to the journal and pin 4 Caps should be installed with the arrow mark directed toward the front of the engine The cap number sequence must be correct 5 Tighte...

Page 128: ...re being tightened to the specified torque 7 Make certain that the crankshaft turns freely and has the proper crankshaft end play Crankshaft end play standard value 0 050 0 250 mm 0 00197 0 0098 in Li...

Page 129: ...tesy of KIA MOTORS AMERICA INC 8 Assemble the rear oil seal to oil case using the special tool 09231 33000 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 32 AM Page 129 200...

Page 130: ...TORS AMERICA INC 9 Install the drive plate and the adapter plate Tightening torque Drive bolt 73 77 N m 730 770 kg cm 53 85 56 80 lb ft 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June...

Page 131: ...g Drive Adapter Plates Courtesy of KIA MOTORS AMERICA INC ENGINE BLOCK COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 32 AM Page 131 2005 Mitchell Repair Informa...

Page 132: ...cylinder head assembly drive plate transaxle mounting plate oil pan and the oil pump case INSPECTING CYLINDER BLOCK 1 Visually check the cylinder block for scores rust and corrosion 2002 Kia Sedona EX...

Page 133: ...enter of cylinder Level 3 Bottom of cylinder Fig 132 Measuring Cylinder Bore Courtesy of KIA MOTORS AMERICA INC 3 If the cylinder bores show more than the specified out of round or taper or if the cyl...

Page 134: ...ance between the oversize piston and the bore and make sure that all pistons used are of the same oversize When measuring the piston outside diameter measure the section of the thrust surface at 10 mm...

Page 135: ...CYLINDER 1 Oversize pistons used should be determined on the basis of the largest bore cylinder PISTON MARK LIMIT CAUTION When the cylinder head is assembled grinding less than 0 2 mm is permissible...

Page 136: ...s to the calculated size 5 Hone the cylinders finishing them to the proper dimension piston outside diameter gap with cylinder 6 Check the clearance between the piston and cylinder OS 25 0 25 mm OS 50...

Page 137: ...Coolant Inlet Flow Courtesy of KIA MOTORS AMERICA INC FLOW CHART NOTE z All cylinders should be bored to the same oversize z Never bore only one cylinder to an oversize 2002 Kia Sedona EX 2002 ENGINES...

Page 138: ...ating Coolant Flow Chart Courtesy of KIA MOTORS AMERICA INC RADIATOR COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 32 AM Page 138 2005 Mitchell Repair Informati...

Page 139: ...isconnect the radiator fan motor connector and the condenser fan motor connector 6 Remove the radiator fan and the condenser fan 7 After marking on the radiator hose and clamp disconnect the upper low...

Page 140: ...open thermostat valve and then stop the engine 3 Remove the radiator cap and fill the radiator with water up to the filler neck and fill the reservoir tank up to the specified level 4 Check if there...

Page 141: ...ICA INC 2 Connect the radiator cap tester to the radiator cap 3 Apply the pressure to the tester untill the needle is fixed 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 3...

Page 142: ...C 4 If the needle stays at the same position for 10 seconds the radiator cap is in good condition RADIATOR FAN MOTOR COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8...

Page 143: ...shroud upper member 5 Disconnect the radiator fan motor connector 6 Remove the radiator fan INSPECTION 1 Radiator fan motor a Check if the radiator fan is rotating when the battery voltage is supplie...

Page 144: ...everse order of disassembly procedure ENGINE WATER PUMP COMPONENTS CAUTION z When assembling the shroud be cautions not to touch the cooling fan z After installing while the fan is operating check if...

Page 145: ...this time do not soak it with oil or grease 3 After installing a new water pump gasket and water pump assembly tighten it to the specified torque see Fig 144 Tightening torque A 5EA 14 7 21 6 N m 150...

Page 146: ...timing belt tension install the timing belt cover 5 After installing the water pump pulley and driving belt adjust the belt tension 6 Refill it with coolant 7 Check for leakage by running the engine...

Page 147: ...e coolant to the bottom level of thermostat 2 Remove the water outlet fitting 3 Remove the thermostat INSPECTION 1 Heat the thermostat and check if the valve operates properly 2002 Kia Sedona EX 2002...

Page 148: ...The temperature when the valve is completely opened 95 C 203 F Fig 146 Testing Thermostat Courtesy of KIA MOTORS AMERICA INC INSTALLATION 1 Align the arrangement mark of thermostat housing with the ji...

Page 149: ...Fig 147 Positioning Thermostat Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 149 2005 Mitchell Repair Information Company LLC...

Page 150: ...inside the intake manifold making it impossible to seat flange in position 3 Install a new gasket and engine coolant outlet fitting Engine coolant outlet fitting bolt tightening torque 17 20 N m 170...

Page 151: ...1 Drain the coolant to the bottom level of the gauge unit 2 After disconnecting the battery ground cable disconnect engine harness 3 Remove the water temperature gauge unit and sensor 2002 Kia Sedona...

Page 152: ...and pipe and replace if necessary WATER TEMPERATURE GAUGE UNIT AND SENSOR 1 Water temperature gauge unit a Heat up the water temperature gauge by immersing it in hot water b Check if the resistance i...

Page 153: ...a Immerse the sensor in hot water b Check if the resistance is within the specified range Fig 151 Temperature Sender Resistance Chart Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINE...

Page 154: ...in water and insert it into the water inlet pipe CAUTION z Be careful not to smear oil or grease on the water pipe O ring z Pay attention not to let a foreign object get into the connecting part of th...

Page 155: ...Fig 153 Positioning Water Pipe O Ring 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 155 2005 Mitchell Repair Information Company LLC...

Page 156: ...e Fig 154 Sealant Tightening Chart Courtesy of KIA MOTORS AMERICA INC 2 Connect the harness to water temperature gauge unit and cable 3 Connect the battery ground cable 4 Refill the coolant AIR CLEANE...

Page 157: ...5 Identifying Air Cleaner Components Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 157 2005 Mitchell Repair Information Compa...

Page 158: ...rtion corrosion and damage 2 Inspect the air duct for damage 3 Inspect the air cleaner element for dirt contamination and damage If element is choked a little blow air from inside of element to get ri...

Page 159: ...for dirt contamination and damage 5 If the inside of air cleaner housing is contaminated eliminates the contaminated material SURGE TANK INTAKE MANIFOLD COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L...

Page 160: ...A MOTORS AMERICA INC REMOVAL 1 Detach the P C V hose and brake booster vacuum hose 2 Disconnect the connecting part of vacuum hose 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08...

Page 161: ...ecting PCV Hose Courtesy of KIA MOTORS AMERICA INC 3 Remove the surge tank stay 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 161 2005 Mitchell Repair Informati...

Page 162: ...INC 4 After reducing the pressure of fuel pipe line to prevent fuel overflow disconnect the connecting part of the high pressure hose 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06...

Page 163: ...g High Pressure Fuel Hose Courtesy of KIA MOTORS AMERICA INC 5 Remove the surge tank 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 163 2005 Mitchell Repair Info...

Page 164: ...Tank Courtesy of KIA MOTORS AMERICA INC 6 After removing the surge tank remove the gasket 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 164 2005 Mitchell Repai...

Page 165: ...Gasket Courtesy of KIA MOTORS AMERICA INC 7 Disconnect the fuel injector harness connector 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 165 2005 Mitchell Repa...

Page 166: ...Remove the delivery pipe with fuel injector and pressure regulator attached CAUTION When removing the delivery pipe be cautions not to drop the injectors 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedon...

Page 167: ...9 Disconnect the wiring harness connector which is connected to the water temperature gauge unit and water temperature sensor assembly 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June...

Page 168: ...t the surge tank for damage and crack if necessary replace it b Check if coolant passage is blocked c Inspect the mating surface for warpage using a straight edge or filler gauge Standard value 0 15 m...

Page 169: ...replacing the intake manifold gasket install the surge tank and tighten to the specified torque Tightening torque 19 6 22 6 N m 200 230 kg cm 14 5 16 6 lb ft 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 S...

Page 170: ...and injector assembly to the intake manifold 3 Install the surge tank stay CAUTION Check the interference between the injector and injector hole in intake manifold 2002 Kia Sedona EX 2002 ENGINES 3 5...

Page 171: ...d actuator 9 Installation of thermostat a Install the water outlet fitting gasket which is attached to thermost at housing Align the arrangement mark on thermost at housing with jiggle valve b Apply t...

Page 172: ...g 170 Exploded View Of Exhaust Manifold Courtesy of KIA MOTORS AMERICA INC REMOVAL 1 Remove the heat protector 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 172...

Page 173: ...Heat Protector Courtesy of KIA MOTORS AMERICA INC 2 Remove the exhaust manifold 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 173 2005 Mitchell Repair Informat...

Page 174: ...ION 1 Exhaust manifold a Check for cracks replace if necessary b Check the distortion in mating surface with a straight edge and filler gauge 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn...

Page 175: ...A INC 2 Heat protector gasket Check for damages and cracks in all parts replace if necessary INSTALLATION 1 After installing the gasket install the exhaust manifold Tightening torque 40 50 N m 400 500...

Page 176: ...of KIA MOTORS AMERICA INC 2 Install the heat protector CAUTION Use only new exhaust manifold gaskets and nuts 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 33 AM Page 176...

Page 177: ...talling Heat Protector Courtesy of KIA MOTORS AMERICA INC MUFFLER COMPONENTS 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 34 AM Page 177 2005 Mitchell Repair Information...

Page 178: ...177 Identifying Muffler Components Courtesy of KIA MOTORS AMERICA INC 2002 Kia Sedona EX 2002 ENGINES 3 5L V6 Sedona Helpmelearn June 06 08 8 54 34 AM Page 178 2005 Mitchell Repair Information Company...

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