2007 KIA CARNIVAL engine

Specification
Limit (Engine coolant temperature : 20°C [68°F])
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)
(2) Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing mark "T" of the
timing chain cover.
(3) With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its clearance are as
shown below.
7.Adjust the intake and the exhaust valve clearances.
(1) Set the piston of the No.1 cylinder to the TDC/position.
(2) Remove the timing belt.
(3) Remove the camshaft bearing caps(A, B).
(4)Remove the camshaft assembly.
(5) Remove MLA(Mechanical Lash Adjuster)s.
(6) Measure the thickness of the removed tappet using a micrometer.
(7)Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
T : Thickness of removed tappet
A : Measured valve clearance

N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]
(8) Select a new tappet with a thickness as close as possible to the calculated value.
Tappets are available with 41different size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to
3.600mm (0.1417in.)
(9) Place a new tappet on the cylinder head.
Apply engine oil on the periphery surface of the selected tappet.
(10) Install the intake and exhaust camshafts.
(11) Install the bearing caps.
(12) Install the timing belt.
(13) Turn the crankshaft two revolutions in the operating direction(clockwise) and realign crankshaft sprocket and
camshaft sprocket timing marks(A).
(14) Recheck the valve clearance.
Specification (Engine coolant temperature: 20°C[68°F])
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

No. 2 ring0.03 ~ 0.07mm(0.0012 ~ 0.0027in.) 0.1mm(0.0039in.)
Oil ring 0.06 ~ 0.15mm(0.0024 ~ 0.0059in.) 0.2mm(0.0079in.)
End gap No. 1 ring 0.15 ~ 0.30mm(0.0059 ~ 0.0118in.) 0.6mm(0.0236in.)
No. 2 ring 0.30 ~ 0.45mm(0.0118 ~ 0.0177in.) 0.7mm(0.0275in.)
Oil ring 0.20 ~ 0.70mm(0.0078 ~ 0.0275in.) 0.8mm(0.0315in.)
Piston ring O.S. 0.25mm(0.0098in.)
Piston pin
Piston pin outer diameter 21.001 ~ 21.007mm(0.8268 ~ 0.8270in.)
Piston pin hole inner diameter 21.014 ~ 21.023mm(0.8273 ~ 0.8277in.)
Piston pin hole clearance 0.007 ~ 0.022mm(0.0003 ~ 0.0009in.)
Connecting rod small end inner diameter 20.974 ~ 20.985mm(0.8257 ~ 0.8262in.)
Connecting rod small end hole clearance 0.016 ~ 0.033mm(0.0006 ~ 0.0013in.)
Connecting rod
Connecting rod big end inner diameter 51.000 ~ 51.018mm(2.0079 ~ 2.0086in.)
Connecting rod bearing oil clearance 0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.) 0.4mm(0.0157in.)
Crankshaft
Main journal outer diameter 61.982 ~ 62.000mm(2.4402 ~ 2.4409in.)
Pin journal outer diameter 47.982 ~ 48.000mm(1.8891 ~ 1.8898in.)
Main bearing oil clearance 0.004 ~ 0.022mm(0.0002 ~ 0.0009in.)
End play 0.07 ~ 0.25mm(0.0028 ~ 0.0098in.) 0.30mm(0.0118in.)
Oil pump
Relief valve opening pressure 490.33 ~ 588.40kPa(5.0 ~ 6.0kgf/cm², 71.12 ~
85.34 psi)
Engine oil
Oil quantity (Total) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil pan) 4.2 L (4.43 US qt, 3.69 lmp qt)
Oil quantity (Drain and refill including oil
filter) 4.5 L (4.75 US qt, 3.95 lmp qt)
Oil quality ABOVE API SJ / SL or SAE 5W- 20
Oil pressure 130kPa(1.32kgf/cm²,18.77psi) [at
1000rpm,110°C(230°F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.2~8.3L(8.66~8.77U.S.qts,7.22~7.30lmp.qts)
Thermostat Type Wax pellet type
Opening temperature 82±2°C (179.6±35.6°F)
Fully opened
temperature 95°C (203°F)
Full lift 10mm (0.3937in.) or more
Radiator cap Main valve opening
pressure 93.16 ~ 122.58kpa(0.95 ~ 1.25 kg/cm², 13.51 ~
17.78psi)

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).

Sustain the engine oil pan with a jack.
(1)
Put a wooden or rubber block between the jack and the engine oil pan.
8. Remove the crankshaft damper pulley(A).
9.Remove the timing belt lower cover(A).
10. Remove the engine support bracket(A).

After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance.
11. Remove the timing belt auto tensioner(A).
12.Remove the timing belt(A).
Make a direction mark of revolution on the timing belt for reusal.
13. Remove the tensioner arm assembly(A) and the idler(B).

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.