2007 KIA CARNIVAL CYLINDER

Valve stem to valve
guide clearanceIntake
0.020 ~ 0.050mm(0.0008 ~ 0.0020in.) 0.10mm(0.0039in.)
or less
Exhaust 0.035 ~ 0.065mm(0.0014 ~ 0.0026in.) 0.13mm(0.0051in.)
or less
Valve guide
Inner diameter Intake 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Exhaust 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Length Intake 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
Exhaust 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
Valve spring
Free length 46.8mm(1.8425in.)
Load Height: 35mm 180.5 ~ 199.5N(18.4 ~ 20.3Kgf, 40.6 ~ 44.8lb)
Height: 26.5mm 342 ~ 378N(34.9 ~ 38.6Kgf, 76.9 ~ 85.1lb)
Out of squareness 1.5° or less
MLA(Mechanical Lash Adjuster)
MLA outer diameter Intake 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Exhaust 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Cylinder head
tappet bore inner
diameter Intake
30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
Exhaust 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
MLA to tappet bore
clearance Intake
0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Exhaust 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Valve clearance
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) 0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.) 0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)
Cylinder block
Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)
Flatness of gasket surface Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
Piston outer diameter 95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
Ring groove width No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)
Piston O.S. 0.25mm(0.0098in.)
Piston ring
Side clearance No. 1 ring 0.04 ~ 0.08mm(0.0016 ~ 0.0031in.) 0.1mm(0.0039in.)

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

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the engine cover.
2. Remove the front right wheel and tire.
3. Remove the right side cover.
4. Remove the drive belt(A), the idler(B) and the tensioner(C).
In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise.
5. Remove the timing belt upper cover(A).
6.Align the groove of the pulley with the timing mark of the timing belt cover by turning the crankshaft pulley
clockwise. Check if the timing mark of the camshaft sprocket is aligned with that of the cylinder head cover at the
moment.
(No.1 cylinder piston at TDC)
7.Remove the engine mounting bracket(A).

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)

Cylinder Head Assembly

2007 > 2.7L V6 GASOLINE >
REMOVAL
a.Use fender covers to avoid damaging painted surfaces.
b. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature before removing it.
c. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
d. To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
a.Mark all wiring and hoses to avoid misconnection.
b. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
1. Remove the air duct and the battery(A) after disconnecting the terminals(B) from the battery.
2.Remove the engine cover.
3. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAF connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).
4.Remove the upper radiator hose(A) and lower radiator hose(B).

8.Disconnect the brake vaccume hose(A).
9.Remove the heater hoses.
10. Remove the drive belt(A).
11.Remove the power steering pump.(Refer to 'ST' group).
12. Remove the exhaust manifold assembly.(Refer to 'Intake and exhause system').
13. Remove the intake manifold assembly.(Refer to 'Intake and exhause system').
14. Remove the timing belt.(Refer to 'Timing system').
15. Remove the ignition coils.
16. Remove the water temp. control assembly.
17. Remove the cylinder head cover(A).

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.