2007 KIA CARNIVAL CYLINDER 6

2.Reprocess the valve guide hole for the oversized valve guide newly installed.
3. Using the SST(09221- 3F100A/B), insert the valve guide in the upside of the cylinder head assembly. Be aware of
the difference in length between the intake and the exhaust valve guides.
Specification
Intake valve guide: 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
Exhaust valve guide: 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
4.After installing the valve guides, insert new valves and check the clearance between the valve stems and the valve
guides.
5. After replacing the valve guides, check if they are properly installed with the valve seats. Reprocess valve seats if
necessary.
INSTALLATION
a.Thoroughly clean all parts to be assembled.
b. Always use a new head and manifold gasket.
c. The cylinder head gasket is a metal gasket. Take care not to bend it.
d. Rotate the crankshaft to set the No.1 cylinder piston at TDC.
1. After putting the cylinder head gasket on the cylinder block, install the cylinder head.

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.

7.Using the SST(09214- 21000), install the camshaft oil seal.
a.Befor installing, apply engine oil.
b. The camshaft cap surface should adhere to the cylinder head assembly.
c. Do not press an eccentric load.
8. Install the CKP sensor connector bracket(A).
9.Install the bank 1 timing belt rear cover(A).
10. Install the bank 2 timing belt rear cover(A).

The length of the bolt(B) is longer than that of the bolt(C).
11. Install the timing belt.(Refer to 'Timing system').
12. Check and adjust the valve clearance.
13. Install the cylinder head cover.
(1) Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover.
(2) Assemble the cylinder head cover in five minites after applying liquid gasket(LOCTITE 5900) on the camshaft
cap and packing part.
(3)Tighten the cylinder head cover bolts as following order(A).
Tightening torque
7.8~9.8Nm(0.8~1.0kgf.m, 5.8~7.2lb- ft)

a.Do not start engine for thirty minites after assembling the cylinder head cover.
b. Do not reuse the cylinder head cover gasket.
14. Install the water temp. control assembly.
15. Install the intake manifold assembly.
16. Install the exhaust mainfold assembly.
17. Install the power steering pump.(Refer to 'ST' group).
18. Install the drive belt(A).
19.Install the heater hose.
20. Connect the brake vaccume hose(A).
21.Install the PCV(Pulge Control Valve) hose(A).
22.Connect the engine wiring harness connectors.
(1) Connect the bank 1 CMP sensor connector(A).

(5)Using SST(09222- 29000), remove the valve stem seal.
Do not reuse the removed valve stem seals.
3. Remove OCV(Oil Control Valve)(A).
INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds
for warpage.
Flatness of cylinder head gasket surface
Standard : 0.03mm(0.0012in.) or less
Flatness of manifold gasket surface
Standard : 0.15mm(0.0059in.) or less
2.Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
VALVE AND VALVE SPRING
1.Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide inside diameter
Intake / Exhaust : 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.)
(2)Using a micrometer, measure the outer diameter of the valve stem.
Valve stem outer diameter
Intake : 5.585 ~ 5.980mm (0.2348 ~ 0.2354in.)
Exhaust : 5.950 ~ 5.595mm (0.2343 ~ 0.2348in.)
(3)Calculate the clearance between the valve guides and the stems by difference between the valve stem
measured diameter and the valve guide measured inside diameter.
Valve stem - to- guide clearance
[Standard]
Intake : 0.020 ~ 0.050mm (0.0008 ~ 0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014 ~ 0.0026in.)
[Limit]
Intake : 0.10mm (0.0039in.) or less
Exhaust : 0.13mm (0.0051in.) or less
2. Inspect valves.
(1) Check the valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.