torque KIA CARNIVAL 2007 Workshop Manual

2007 > 2.7L V6 GASOLINE >
SPECIAL TOOLS
Tool (Number and name) Illustration Use
Crankshaft front oil seal
installer
(09214- 33000)
Installation of the front oil seal
Torque angle adapter
(09221- 4A000)
Installation of bolts & nuts needing an angular
method
Valve stem seal remover
(09222- 29000)
Removal of the valve stem seal
Valve stem seal installer
(09222- 22001)
Installation of the valve stem seal
Camshaft oil seal installer
(09214- 21000)
Installation of the camshaft oil seal
Valve spring compressor &
holder
(09222- 3K000)
(09222- 3C300)
Removal and installation of the intake or
exhaust valves.
A : 09222 - 3K000
B : 09222 - 3C300 (holder)
Crankshaft rear oil seal Installation of the crankshaft rear oil seal

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

14.Remove the crankshaft sprocket.
INSTALLATION
1.Install the crankshaft sprocket.
2. Install the tensioner arm assembly(A) and the idler(B).
Tightening torque
Tensioner arm bolt : 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3~ 39.8lb- ft)
Idler pulley bolt : 49.0 ~ 58.8Nm(5.0 ~ 6.0kgf.m, 36.2~ 43.4lb- ft)
3.Install the timing belt auto tensioner.
(1) Fixing the tensioner with a vice and compressing the rod, insert a set- pin.
a.Handle the auto tensioner in the vertical position.
b. If it is treated by laying, tilting or turning over, stand it vertically for about five minutes in order for air to
move upward.
c. Do not pull the pin out before its installation to the engine assembly because pulling the pin can cause
noise of timing system by making aiir go in the high pressure chamber.

a.When pressing the rod, use a vertical vice certainly.
b. There is a high possibility for air to get in the high pressure chamber, when using a horizotal vice.
c. Do not apply more load than 400N on the rod.
d. Do not press the rod until its position is below 2.5mm from the body surface.
e. The projection of the rod is secured more than 2.5mm.
a.Repairing orders when disassembling the auto tensioner and reassembling it to the engine, or pulling
the pin out before its installation ;
a. Stand it vertically for about five minutes.
b. Press the rod with the force, 150~200N.
c. If the rod has a stiffness, press it slowly and insert the pin into the set hole.
d. If not(the tensioner is in 'sponge' state), press the rod slowly from its maximum projection to 2.9mm
position(the meeting point with the rod and the hole of the body) two or three times.
Afterwards, if stiffness is sensed, insert the pin into the hole. However, if not, scrap the tensioner.
(2) Install the auto tensioner(A) to the front case with the set- pin inserted.
Tightening torque
19.6 ~ 26.5Nm(2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb- ft)
4.Ensure the timing marks on the camshaft and the crankshaft sprockets.
5.Install the timing belt.
Crankshaft sprocket(A) → Idler(B) → Bank 2 exhaust camsprocket(C) → Water pump pulley(D) → Bank 1 exhaust
camsprocket(E) → Tensioner pulley(F).

6.Remove the auto tensioner set- pin.
7. Check the tension of the timing belt.
(1) Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at TDC.
After 5minutes, measure the length of the projected rod.
Specification
5 ~ 7mm(0.1969 ~ 0.2756in.)
(2)Ensure the locations of the timing marks for each sprocket.
8. Install the engine support bracket(A).
Tightening torque
58.8 ~ 68.6Nm(6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb- ft)
9.Install the timing belt lower cover(A).
Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.8 ~ 8.7lb - ft)

10.Install the crankshaft damper pulley(A).
Tightening torque
166.7 ~ 176.5Nm(17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb- ft)
11.Install the engine mounting bracket(A).
Tightening torque
63.7 ~ 83.4Nm(6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb- ft)
12.Install the timing belt upper cover(A).
Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb - ft)

13.Install the drive belt tensioner(C).
Tightening torque
34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb- ft)
14. Install the drive belt idler and the drive belt(A).
Tightening torque
34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb- ft)
15.Install the right side cover.
16. Install the front right wheel and tire.
17. Install the engine cover.
INSPECTION
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket and crankshaft sprocket, tensioner pulley and idler pulley for abnormal wear, cracks,
or damage. Replace as necessary.
2. Inspect the tensioner and the idler for easy and smooth rotation and check for play or noise. Replace as necessary.

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.