2007 KIA CARNIVAL Workshop Manual

ClassSize code Piston outer diameter
A A86.67 ~ 86.68mm
(3.4122 ~ 3.4126in.)
B -86.68 ~ 86.69mm
(3.4126 ~ 3.4130in.)
C C86.69 ~ 86.70mm
(3.4130 ~ 3.4134in.)
8. Select the proper piston related to the cylinder bore class.
Clearance : 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
CYLINDER BORING
1.The over size piston is chosen on the maximum inner diameter of the cylinder.
The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.
3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 ~ 0.04mm(0.0008~0.0016in.)[clearance] -
0.01mm(0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
Bore the cylinders in firing order to prevent the cylinders from be twisted by high temperature.
5. Stop boring and start horning for the proper clearance.
6. Measure the clearance between a piston and a cylinder.
Specification
0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
Bore all the cylinders with the same over size.
PISTON AND RINGS
1.Clean pistons.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the
piston.

Standard diameter
86.67 ~ 87.00(3.4122 ~ 3.4252in.)
3.Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston - to- cylinder clearance
0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the ring groove.
Piston ring side clearance
Standard
No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
If the clearance is greater than the maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is
over the service limit, the cylinder block must be replaced or bored
Piston ring end gap
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.30 ~ 0.45m (0.0118 ~ 0.0177in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit

No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)
PISTON PINS
1.Measure the outer diameter of the piston pin.
Piston pin outer diameter
21.001 ~ 21.007mm (0.8268 ~ 0.8270in.)
2. Measure the piston pin- to- piston clearance.
Piston pin- to- piston clearance
0.007 ~ 0.022mm (0.0003 ~ 0.0009in.)
3. Check the difference between the piston pin outer diameter and the connecting rod small end inner diameter.

Piston pin- to- connecting rod interference
- 0.033 ~ - 0.016mm ( - 0.0013 ~ - 0.0006in.)
REASSEMBLY
a.Thoroughly clean all parts before reassembling.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O - rings and oil seals with new parts.
1. Assemble the piston and the connecting rod.
(1) Use a hydraulic press for installation.
(2) The piston front mark(A) and the connecting rod front mark must face the timing belt side of the engine.
2.Install piston rings.
(1) Install the oil ring spacer and 2 side rails by hand.
(2) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
(3) Position the piston rings so that the ring ends are as shown.
3.Install the connecting rod bearings.
(1) Align the bearing(A) claw with the groove of the connecting rod or connecting rod cap(B).
(2) Install the bearings(A) in the connecting rod and connecting rod cap(B).

When reassembling the connecting rods and the caps, ensure the front marks on them.
4. Install the CKP sensor(A).
Tightening torque
6.9 ~ 9.8Nm(0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb - ft)
5.Install main bearings.
Upper bearings have the oil grooves of the oil holes; Lower bearings do not.
(1) Aligning the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A).

(2)Aligning the bearing claw with the claw groove of the main bearing cap, push in the 4 lower bearings(B) on the
bearing caps(A).
6.Install thrust bearings.
Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.
7.Place crankshaft(A) on the cylinder block.
8.Place main bearing caps on cylinder block.
9. Install main bearing cap bolts.
(1) Install and uniformly tighten the bearing cap bolts, in two steps, in the sequence shown.
Tightening torque

M8 : 15.7Nm(1.6 kgf.m, 11.6lb- ft) + 90°
M10 : 29.4Nm(3.0 kgf.m, 21.7lb- ft)+ 90°
a.Use new main bearing cap bolt with engine oil applied.
b. If any of the bearing cap bolts are broken or deformed, replace it.
c. Washers have their direction(Up/Down)
d. Assemble the bearing cap bridge on which its arrow mark faces the engine front.
e. Before tightening, make the bearing caps be seated on the block firmly.
Use SST( 09221 - 4A000 ), install main bearing cap bolts.
(2) Check that the crankshaft turns smoothly.
10. Check crankshaft end play.
11. Install the piston and connecting rod assemblies.
a.Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
b. When installing the piston, ensure that the coat on the cylinder wall is not damaged or scratched.
(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(2) Stop inserting the piston when the ring inserted in the cylinder and check the alignment of the journal and the
connecting rod.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque

19.6Nm (2.0kgf.m, 14.46lb- ft) + 90°
a.Always use new connecting rod bolts.
b. Maintain downward force on the ring compressor to prevent the rings from expanding before entering
the cylinder bore.
c.Use SST(09221- 4A000), install connecting rod bearing cap bolts.
12. Install the rear oil seal case.
Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb- ft)