KIA CARNIVAL 2007 User Guide

Seized crankshaft or connecting rod bearings.a.Inspect crankshaft and connecting rod
bearing.
b. Repair as required.
Bent or broken connecting rod. a.Inspect connecting rods.
b. Repair as required.
Broken crankshaft. a.Inspect crankshaft.
b. Repair as required.

2007 > 2.7L V6 GASOLINE >
Compression pressure inspection
If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.
1. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F).
2. Remove the surge tank.
3. Remove the ignition coil connectors(B) and ignition coils.
4.Using a 16mm plug wrench, remove the 6 spark plugs.
5. Check cylinder compression pressure.
(1) Insert a compression gauge into the spark plug hole.
(2) Open the throttle fully.
(3) With the fully - open throttle in cranking, measure the compression pressure.
Always use a fully charged battery to get the engine speed of 250 rpm or more.
Repeat steps 1) through 3) for each cylinder.
This measurement must be done in as short a time as possible.
Compression pressure: 1,176.79kPa (12.0kgf/cm², 170.68psi) - 200 ~ 250rpm
Minimum pressure: 1,029.69kPa (10.5kgf/cm², 149.34psi)
Difference between cylinders: 98.07kPa (1.0kgf/cm², 14.22psi)
(4) If the compression pressure in 1 or more cylinders is lower than the specification above, pour a small amount
of engine oil into the cylinder through the spark plug hole, repeat the steps (1) through (3) for the cylinder and
measure the pressure again.
a. If adding oil increases the pressure up, the piston rings or cylinder bores might be worn or damaged.
b. If the pressure doesn't increase, a valve may be sticking or seating may be improper, or there may be
leakage from the gasket.
6. Reinstall the spark plugs.
7. Install the ignition coils and connect ignition coil connectors.
8. Install the surge tank.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C
±5°C(59~77°F)) and cylinder head is installed on the cylinder block.

1.Remove the engine cover.
2. Remove air cleaner assembly.
3. Remove the surge tank.
4. Remove the cylinder head cover.
(1) Disconnect the ignition coil connector and remove the ignition coil.
(2) Remove the cylinder head cover.
5.Set the piston of the No.1 cylinder to TDC(Top Dead Center) position.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the timing chain cover.
(2) Check that the timing marks of the camshaft sprocket are in straight line on that of the cylinder head cover
surface as shwn in the illustration. It makes the piston of the No.1 cylinder position at TDC.
If not, turn the crankshaft one revolution clockwise.
6. Inspect the intake and the exhaust valve clearance.
(1) With the piston of the No.1 cylinder positioning at TDC, the valves which can be measured its clearance are as
shown below.
Measurement method.
a. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
b. Record the out - of- specification valve clearance measurements. They will be used later to determine the
required adjusting tappet for replacement.

Specification
Limit (Engine coolant temperature : 20°C [68°F])
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
(2) Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing mark "T" of the
timing chain cover.
(3) With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its clearance are as
shown below.
7.Adjust the intake and the exhaust valve clearances.
(1) Set the piston of the No.1 cylinder to the TDC/position.
(2) Remove the timing belt.
(3) Remove the camshaft bearing caps(A, B).
(4)Remove the camshaft assembly.
(5) Remove MLA(Mechanical Lash Adjuster)s.
(6) Measure the thickness of the removed tappet using a micrometer.
(7)Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T : Thickness of removed tappet
A : Measured valve clearance

N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]
(8) Select a new tappet with a thickness as close as possible to the calculated value.
Tappets are available with 41different size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to
3.600mm (0.1417in.)
(9) Place a new tappet on the cylinder head.
Apply engine oil on the periphery surface of the selected tappet.
(10) Install the intake and exhaust camshafts.
(11) Install the bearing caps.
(12) Install the timing belt.
(13) Turn the crankshaft two revolutions in the operating direction(clockwise) and realign crankshaft sprocket and
camshaft sprocket timing marks(A).
(14) Recheck the valve clearance.
Specification (Engine coolant temperature: 20°C[68°F])
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Description SpecificationsLimit
General
Type V- type, DOHC
Number of cylinder 6
Bore 86.7mm(3.4134in.)
Stroke 75mm(2.9528in.)
Total displacement 2,656cc
Compression ratio 10.4
Firing order 2 - 3 - 4 - 5 - 6 - 1
Valve timing
Intake valve Opens (ATDC) 4° ~ - 56°
Closes (ABDC) 60° ~ 0°
Exhaust valve Opens (BBDC) 46°
Closes (ATDC) 10°
Cylinder head
Flatness of gasket surface 0.03mm(0.0012in.) or less 0.05mm(0.0020in.)
Flatness of
manifold mounting Intake
0.15mm(0.0059in.) or less
Exhaust 0.15mm(0.0059in.) or less
Camshaft
Cam height LH
CamshaftIntake
44.5mm(1.7520in.)
Exhaust 44.5mm(1.7520in.)
RH
Camshaft Intake
44.5mm(1.7520in.)
Exhaust 44.5mm(1.7520in.)
Journal outer
diameter LH
CamshaftIntake
27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Exhaust 27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
RH
Camshaft Intake
27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Exhaust 27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Bearing oil
clearance Intake
0.020 ~ 0.057mm(0.0008 ~ 0.0022in.)
Exhaust 0.020 ~ 0.057mm(0.0008 ~ 0.0022in.)
End play 0.05 ~ 0.15mm(0.0020 ~ 0.0059in.)
Valve
Valve length Intake 110.1mm(4.3346in.)
Exhaust 111.1mm(4.3740in.)
Stem outer
diameter Intake
5.965 ~ 5.980mm(0.2348 ~ 0.2354in.)
Exhaust 5.950 ~ 5.965mm(0.2343 ~ 0.2348in.)
Face angle 45° ~ 45.5°
Thickness of
valvehead(margin) Intake
1.0mm(0.0394in.)
Exhaust 1.3mm(0.0512in.)

Valve stem to valve
guide clearanceIntake
0.020 ~ 0.050mm(0.0008 ~ 0.0020in.) 0.10mm(0.0039in.)
or less
Exhaust 0.035 ~ 0.065mm(0.0014 ~ 0.0026in.) 0.13mm(0.0051in.)
or less
Valve guide
Inner diameter Intake 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Exhaust 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Length Intake 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
Exhaust 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
Valve spring
Free length 46.8mm(1.8425in.)
Load Height: 35mm 180.5 ~ 199.5N(18.4 ~ 20.3Kgf, 40.6 ~ 44.8lb)
Height: 26.5mm 342 ~ 378N(34.9 ~ 38.6Kgf, 76.9 ~ 85.1lb)
Out of squareness 1.5° or less
MLA(Mechanical Lash Adjuster)
MLA outer diameter Intake 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Exhaust 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Cylinder head
tappet bore inner
diameter Intake
30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
Exhaust 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
MLA to tappet bore
clearance Intake
0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Exhaust 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Valve clearance
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) 0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.) 0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)
Cylinder block
Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)
Flatness of gasket surface Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
Piston outer diameter 95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
Ring groove width No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)
Piston O.S. 0.25mm(0.0098in.)
Piston ring
Side clearance No. 1 ring 0.04 ~ 0.08mm(0.0016 ~ 0.0031in.) 0.1mm(0.0039in.)

No. 2 ring0.03 ~ 0.07mm(0.0012 ~ 0.0027in.) 0.1mm(0.0039in.)
Oil ring 0.06 ~ 0.15mm(0.0024 ~ 0.0059in.) 0.2mm(0.0079in.)
End gap No. 1 ring 0.15 ~ 0.30mm(0.0059 ~ 0.0118in.) 0.6mm(0.0236in.)
No. 2 ring 0.30 ~ 0.45mm(0.0118 ~ 0.0177in.) 0.7mm(0.0275in.)
Oil ring 0.20 ~ 0.70mm(0.0078 ~ 0.0275in.) 0.8mm(0.0315in.)
Piston ring O.S. 0.25mm(0.0098in.)
Piston pin
Piston pin outer diameter 21.001 ~ 21.007mm(0.8268 ~ 0.8270in.)
Piston pin hole inner diameter 21.014 ~ 21.023mm(0.8273 ~ 0.8277in.)
Piston pin hole clearance 0.007 ~ 0.022mm(0.0003 ~ 0.0009in.)
Connecting rod small end inner diameter 20.974 ~ 20.985mm(0.8257 ~ 0.8262in.)
Connecting rod small end hole clearance 0.016 ~ 0.033mm(0.0006 ~ 0.0013in.)
Connecting rod
Connecting rod big end inner diameter 51.000 ~ 51.018mm(2.0079 ~ 2.0086in.)
Connecting rod bearing oil clearance 0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.) 0.4mm(0.0157in.)
Crankshaft
Main journal outer diameter 61.982 ~ 62.000mm(2.4402 ~ 2.4409in.)
Pin journal outer diameter 47.982 ~ 48.000mm(1.8891 ~ 1.8898in.)
Main bearing oil clearance 0.004 ~ 0.022mm(0.0002 ~ 0.0009in.)
End play 0.07 ~ 0.25mm(0.0028 ~ 0.0098in.) 0.30mm(0.0118in.)
Oil pump
Relief valve opening pressure 490.33 ~ 588.40kPa(5.0 ~ 6.0kgf/cm², 71.12 ~
85.34 psi)
Engine oil
Oil quantity (Total) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil pan) 4.2 L (4.43 US qt, 3.69 lmp qt)
Oil quantity (Drain and refill including oil
filter) 4.5 L (4.75 US qt, 3.95 lmp qt)
Oil quality ABOVE API SJ / SL or SAE 5W- 20
Oil pressure 130kPa(1.32kgf/cm²,18.77psi) [at
1000rpm,110°C(230°F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.2~8.3L(8.66~8.77U.S.qts,7.22~7.30lmp.qts)
Thermostat Type Wax pellet type
Opening temperature 82±2°C (179.6±35.6°F)
Fully opened
temperature 95°C (203°F)
Full lift 10mm (0.3937in.) or more
Radiator cap Main valve opening
pressure 93.16 ~ 122.58kpa(0.95 ~ 1.25 kg/cm², 13.51 ~
17.78psi)

Vacuum valve opening
pressure0.98 ~ 4.90 kpa(0.01 ~ 0.05 kg/cm², 0.14 ~ 0.71
psi)
Engine coolant temperature sensor
Type Thermister type
Resistance 20°C (68°F) 2.31 ~ 2.59 kΩ
80°C(176°F) 0.3222 kΩ
TIGHTENING TORQUE
Item QuantityNmkgf.m lb- ft
Oil seal case bolt 39.8 ~ 11.8 1.0 ~ 1.27.2 ~ 8.7
Main bearing cap bolt(M10) 829.4 + 90° 3.0 + 90°21.7 + 90°
Main bearing cap bolt(M8) 815.7 + 90° 1.6 + 90°11.6 ~ + 90°
Rear plate bolt 19.8 ~ 11.8 1.0 ~ 1.27.2 ~ 8.7
Oil pump case bolt(8×25) 118.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Oil pump case bolt(8×35) 118.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
TimingOil pump case bolt(8×65) 118.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
TimiOil relief plug 139.2 ~ 49.0 4.0 ~ 5.028.9 ~ 36.2
Oil filter bracket bolt(8×35) 418.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Oil filter bracket bolt(8×65) 218.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Oil filter insert 144.1 ~ 53.9 4.5 ~ 5.532.5 ~ 39.8
Timing chain cover bolt 219.8 ~ 11.8 1.0 ~ 1.27.2 ~ 8.7
Upper oil pan bolt(8×22) 1518.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Upper oil pan bolt(163.5mm) 14.9 ~ 6.9 0.5 ~ 0.73.6 ~ 5.1
Upper oil pan bolt(154.5mm) 14.9 ~ 6.9 0.5 ~ 0.73.6 ~ 5.1
Lower oil pan bolt 119.8 ~ 11.8 1.0 ~ 1.27.2 ~ 8.7
Oil drain plug 134.3 ~ 44.1 3.5 ~ 4.525.3 ~ 32.5
Engine support bracket bolt(10×94) 258.8 ~ 68.6 6.0 ~ 7.043.4 ~ 50.6
Engine support bracket bolt(10×102.5) 158.8 ~ 68.6 6.0 ~ 7.043.4 ~ 50.6
Camshaft bearing cap bolt(6×38) 2410.8 ~ 12.7 1.1 ~ 1.38.0 ~ 9.4
Camshaft bearing cap bolt(8×38) 1220.6 ~ 25.5 2.1 ~ 2.615.2 ~ 18.8
Cylinder head bolt 1622.6~26.5 + (60°
+2°) + (45°+2°) 2.3~2.7 + (60°
±2°) + (45°±2°) 16.6~19.5 + (60°
+2°) + (45°+2°)
Cylinder head cover bolt 227.8 ~ 9.8 0.8 ~ 1.05.8 ~ 7.2
Crankshaft pulley bolt 1166.7 ~ 176.5 17.0 ~ 18.0123.0 ~ 130.2
Drive plate bolt 871.6 ~ 75.5 7.3 ~ 7.752.8 ~ 55.7
Connecting rod bearing cap bolt 1219.6 ~ 90° 2.0 ~ 90°14.5 ~ 90°
OCV(Oil Control Valve) bolt 27.8 ~ 9.8 0.8 ~ 1.05.8 ~ 7.2
CVVT & exhaust cam sprocket bolt 466.7 ~ 78.5 6.8 ~ 8.049.2 ~ 57.9
Timing chain auto tensioner bolt 410.8 ~ 12.7 1.1 ~ 1.38.0 ~ 9.4
Camshaft sprocket bolt 288.3 ~ 107.9 9.0 ~ 11.065.1 ~ 79.6
Timing belt idler bolt 149.0 ~ 58.8 5.0 ~ 6.036.2 ~ 43.4

Timing belt tensioner bolt219.6 ~ 26.5 2.0 ~ 2.714.5 ~ 19.5
Timing belt tensioner arm bolt 134.3 ~ 53.9 3.5 ~ 5.525.3 ~ 39.8
Water pump bolt(8×20) 314.7 ~ 21.6 1.5 ~ 2.210.8 ~ 15.9
Water pump bolt(8×25) 414.7 ~ 21.6 1.5 ~ 2.210.8 ~ 15.9
Drive belt idler bolt 134.3 ~ 53.9 3.5 ~ 5.525.3 ~ 39.8
Drive belt tensioner bolt 134.3 ~ 53.9 3.5 ~ 5.525.3 ~ 39.8
Water pipe bolt 116.7 ~ 19.6 1.7 ~ 2.012.3 ~ 14.5
Water temp. control assembly nut 429.4 ~ 41.2 3.0 ~ 4.221.7 ~ 30.4
Oil level gauge bolt 118.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Oil screen bolt 214.7 ~ 21.6 1.5 ~ 2.210.8 ~ 15.9
Water outlet pipe bolt 316.7 ~ 19.6 1.7 ~ 2.012.3 ~ 14.5
Water inlet pipe bolt 216.7 ~ 19.6 1.7 ~ 2.012.3 ~ 14.5
Water inlet pipe nut 116.7 ~ 19.6 1.7 ~ 2.012.3 ~ 14.5
Surge tank bolt(8×28) 318.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Surge tank bolt(8×80) 218.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Surge tank nut 218.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Intake manifold bolt 418.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Intake manifold nut 418.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Surge tank bracket bolt 218.6 ~ 23.5 1.9 ~ 2.413.7 ~ 17.4
Exhaust manifold bolt 1429.4 ~ 34.3 3.0 ~ 3.521.7 ~ 25.3
Heat protect bolt 616.7 ~ 21.6 1.7 ~ 2.212.3 ~ 15.9
Front muffler bolt 239.2 ~ 58.8 4.0 ~ 6.028.9 ~ 43.4