KIA CARNIVAL 2007 Manual PDF

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :a. Adjust the shift cable.
b. Refill the engine with engine oil.
c. Refill the transaxle with fluid.
d. Refill the radiator with engine coolant.
e. Bleed air from the cooling system with the heater valve open.
f. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
g. Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

Cylinder Block

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2007 > 2.7L V6 GASOLINE >
COMPONENTS

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the drive plate(A).
2.Remove the rear plate(A).
3.Remove timing belt.
4. Remove intake manifold.
5. Remove exhaust manifold.
6. Remove generator from engine.(Refer to 'ST' group).
7. Remove power steering pump from engine.(Refer to 'HA' group).
8. Remove cylinder head.
9. Remove A/C compressor from engine.(Refer to 'EE' group).
10. Remove water pump assembly.
INSTALLATION
1.Install the water pump.
2. Install the air conditioning compressor.(Refer to 'HA' group).
3. Install the cylinder head.
4. Install the power steering pump.(Refer to 'ST' group).
5. Install the generator.
6. Install the intake manifold.
7. Install the exhaust manifold.
8. Install the timing belt.
9. Install the rear plate(A).
Tightening torque

9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb - ft)
10.Install the drive plate(A).
Tightening torque
71.6 ~ 75.5Nm(7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb- ft)
DISASSEMBLY
1.Remove the power steering pump bracket(A) and the knock sensor(B).
2.Remove the air conditioning compressor bracket(A).

3.Remove the lower oil pan(A).
4.Remove the oil screen(A).
5.Remove the upper oil pan(A).
When removing the oil pan, use the SST(09215- 3C000) not to damage the contacting surface of the oil pan.

6.Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.
a.Keep the bearings the connecting rods and the caps together.
b. Arrange the piston and connecting rod assemblies in the correct order.
9. Remove the oil pump case.
10. Remove the oil seal case(A).
11.Check the crankshaft end play.
12. Remove the crankshaft bearing cap and check oil clearance.
Arrange the bearings and the bearing caps in order.
13. Lift the crankshaft(A) out of the block, being careful not to damage journals.

14.Remove and arrange the main bearings and thrust bearings in the correct order.
15.Remove the CKP sensor(A).
16.Check the free play between a piston and a piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston
pin as a set.
17. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove the 2 side rails and the oil ring by hand.

Arrange the piston rings in the correct order only.
18. Disconnect the connecting rod from the piston.
Using a press, remove the piston pin from the piston.
(Press- in load : 2451.7 ~ 12258.3N(250 ~ 1250kg, 551.2 ~ 2755.81lb)
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.
Specification
Standard : 0.1~ 0.25mm(0.0039 ~ 0.0098in.)
Limit : 0.4mm(0.0157in.)
a.If out - of- tolerance, install a new connecting rod.
b. If still out - of- tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and the lower bearing.
(4) Clean the crankshaft pin journal and the bearing.
(5) Place a plastigage across the crankshaft pin.
(6) Reinstall the lower bearing and the connecting rod cap and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb- ft) + 90°
Do not turn the crankshaft.
(7) Remove the connecting rod cap again.
(8) Measure the plastigage at its widest point.
Standard oil clearance
0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)