KIA CARNIVAL 2007 Service Manual

23.Remove the CKP sensor connector bracket(A).
24.Remove the cylinder head assembly.
(1) Remove the bolts in 2~3 steps as following orders.
If the bolts are not removed as the order, the deformation of the head assembly can be occurred.
(2) Put the cylinder head assembly on a wooden block after removal from the cylinder block.
Ensure that the surface between the cylinder head and the block is not damaged.
REPLACEMENT
Valve guide
1. Using the SST(09221- 3F100A), remove the valve guide from the downside of the cylinder head assembly.

2.Reprocess the valve guide hole for the oversized valve guide newly installed.
3. Using the SST(09221- 3F100A/B), insert the valve guide in the upside of the cylinder head assembly. Be aware of
the difference in length between the intake and the exhaust valve guides.
Specification
Intake valve guide: 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
Exhaust valve guide: 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
4.After installing the valve guides, insert new valves and check the clearance between the valve stems and the valve
guides.
5. After replacing the valve guides, check if they are properly installed with the valve seats. Reprocess valve seats if
necessary.
INSTALLATION
a.Thoroughly clean all parts to be assembled.
b. Always use a new head and manifold gasket.
c. The cylinder head gasket is a metal gasket. Take care not to bend it.
d. Rotate the crankshaft to set the No.1 cylinder piston at TDC.
1. After putting the cylinder head gasket on the cylinder block, install the cylinder head.

Ensure the LH/RH classification of the cylinder head gasket when installing.
2. Tighten the cylinder head bolts with the plain washers in several steps as following order.
a.In assembling washers, the marked surface should face upward.
b. In installing the cylinder head bolts, apply engine oil on the thread of the bolts and the surface of the
washers.
Tightening torque
22.6~26.5Nm(2.3~2.7kgf.m, 16.6~19.5lb - ft) + (60° + 2°) + (45° + 2°)
Using the SST(09221- 4A000), tighten the bolts which need to be tightened with the angular tightening method.
3. Install the CVVT assembly and camshaft chain sprocket with the dowel pin in the CVVT installed to the intake
camshaft. Ensure that the pin will not be installed in the hole for oil feeding.

camshaft. Ensure that the pin will not be installed in the hole for oil feeding.
Tightening torque
66.7~78.5Nm(6.8~8.0kgf.m, 49.2~57.9lb - ft)
After tightening the CVVT bolts, rotate the CVVT assembly housing counterclockwise by hand to seat the lock
pin in the CVVT assembly in good position.
Fix the hexagonal part of the camshaft in a vice when tightening the CVVT bolts. Do not fix the CVVT housing
or sprocket in a vice.
4. Install the camshaft in the cylinder head assembly.
(1) Align the timing mark of the camshaft timinig chain.
LH camshaft chain timing mark
RH camshaft chain timing mark
Both timing marks should face upward in reassemby.
5. Install the timing chain tensioner.
(1) Insert the set pin by pressing the timing chain tensioner.
(2) Install the chain tensioner(A) in the cylinder head assembly.

6.Install the camshaft bearing caps.
Tightening torque
Bearing cap bolt(A: 6×38) - 10.8~12.7Nm(1.1~1.3kgf.m, 8.0~9.4lb- ft)
Bearing cap bolt(B: 8×38) - 20.6~22.5Nm(2.1~2.6kgf.m, 15.2~18.8lb - ft)
When installing the bearing caps, check the marks on them as shown below and install them in its proper
position.
A(LH/RH HEAD): L(LH), R(RH)
B(Intake/Exhaust): I(Intake), E(Exhaust)
C(Cap no.): 1,2,3
When installing the bearing caps, turn the crankshaft to place a piston in the middle of the block because
linterference between valves and pistons can occur.

7.Using the SST(09214- 21000), install the camshaft oil seal.
a.Befor installing, apply engine oil.
b. The camshaft cap surface should adhere to the cylinder head assembly.
c. Do not press an eccentric load.
8. Install the CKP sensor connector bracket(A).
9.Install the bank 1 timing belt rear cover(A).
10. Install the bank 2 timing belt rear cover(A).

The length of the bolt(B) is longer than that of the bolt(C).
11. Install the timing belt.(Refer to 'Timing system').
12. Check and adjust the valve clearance.
13. Install the cylinder head cover.
(1) Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover.
(2) Assemble the cylinder head cover in five minites after applying liquid gasket(LOCTITE 5900) on the camshaft
cap and packing part.
(3)Tighten the cylinder head cover bolts as following order(A).
Tightening torque
7.8~9.8Nm(0.8~1.0kgf.m, 5.8~7.2lb- ft)

a.Do not start engine for thirty minites after assembling the cylinder head cover.
b. Do not reuse the cylinder head cover gasket.
14. Install the water temp. control assembly.
15. Install the intake manifold assembly.
16. Install the exhaust mainfold assembly.
17. Install the power steering pump.(Refer to 'ST' group).
18. Install the drive belt(A).
19.Install the heater hose.
20. Connect the brake vaccume hose(A).
21.Install the PCV(Pulge Control Valve) hose(A).
22.Connect the engine wiring harness connectors.
(1) Connect the bank 1 CMP sensor connector(A).

(2)Connect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C).
(3)Connect the bank 2 CMP sensor connector(A) and the WTS(Water Temperature Sensor) connector(B).
(4)Connect the generator connector(A) and the air conditioning compressor connector(B).
(5)Connect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control)
connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C).

(6)Connect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the
No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E).
(7)Connect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil
connectors(F).
(8)Connect the bank 1 front/rear O2 sensor connectors(A).