2007 KIA CARNIVAL Workshop Manual

In the installation of the oil pump, always use a new o - ring(B).
3. Using the SST(09214~33000), install the oil pump case oil seal.
4.Install the upper oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
a.Make clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not be protrude into the inside of oil pan.

d.To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
e. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
Bolts 1~15 : 18.6 ~ 23.5Nm(1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb- ft)
Bolts 16,17 : 4.9 ~ 6.9Nm(0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb - ft)
5.Install the oil screen.
Tightening torque
14.7 ~ 21.6Nm(1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb- ft)
Always use a new gasket.
6. Install the lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.
The part must be assembled within 5 minutes after the sealant was applied.

a.Make clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not be protrude into the inside of oil pan.
d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
e. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb - ft)
7.Install the oil filter bracket(A).
Tightening torque
18.6 ~ 23.5Nm(1.9 ~ 2.4kgf.m, 13.7~ 17.4lb- ft)

Always use a new O - ring.
8. Install the timing belt, the generator and the front muffler.
9. Install the front right side cover and the wheel and tire.
10. Fill with engine coolant.
11. Start engine and check for leaks.
12. Recheck engine coolant level.
INSPECTION
1.Check engine oil quality.
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace oil.
2. Check the engine oil level.
After warning up the engine, make the engine stand still for five minutes or more. The oil level should be between
the 'L' and 'F' marks on the dipstick, then.
If low, check for leakage and add oil up to the "F" mark.
Do not fill with engine oil above the "F" mark.
SELECTION OF ENGINE OIL
Recommended API classification : Above SJ or SL
Recommended SAE viscosity grades : 5W- 20

For best performance and maximum protection of all types of operation, select only those lubricants which :a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
RELIEF SPRING
1.Check the relief plunger.
Apply engine oil on the plunger and check that it moves smoothly in the hole. If it does not, replace the plunger or
the front case only in necessary cases.
2. Check the relief valve spring.
Check deformation or damage of the relief valve spring.
Specification
Free length : 43.8mm(1.7244in.)
Load : 36.3N(3.7kg, 8.21b)±3.9N(0.4kg, 0.9lb) / 40.1mm(1.5787in.)
OIL PRESSURE SWITCH
1.Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.

2.Check the continuity between the terminal and the body when its hole is pushed by a fine rod(A). If there is
continuity with pressed, replace the switch.
3.If there is no continuity when the pressure 49.3kpa (0.5kg/cm², 7.11psi) is applied through the oil hole, the switch
is operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace the switch.

Intakeand
Exhaust system

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COMPONENTS