2007 KIA CARNIVAL CYLINDER

If the margin thickness is less than the specification, replace the valve.
Specification
Intake : 1.0mm(0.0394in.)
Exhaust : 1.3mm(0.0512.)
(4)Check the valve length.
Length
Intake : 110.1mm(4.3346in)
Exhaust : 111.1mm(4.3740in)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
(1) Check the valve seat for evidence of overheating or improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace the valve
guide first.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out - of- square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 46.8mm (1.8425in.)
Out- of- square : 1.5° or less

MLA(Mechanical Lash Adjuster)
1.Inspect MLA.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust : 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust : 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
3. Calculate the clearance by subtracting MLA outside diameter measurement from tappet bore inside diameter
measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.) or less
CAMSHAFT
1.Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.5mm (1.7520in.)
Exhaust : 44.5mm (1.7520in.)
If the cam lobe height is less than standard, replace the camshaft.
2. Check the cam lobe surface for wear or damage. If necessary, replace it.
3. Inspect camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.

(4)Install the bearing caps with the tightening torque.
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
Exhaust : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
4. Inspect camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.05 ~ 0.15mm(0.0020 ~ 0.0059in.)

If the end play is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head.
(3) Remove the camshafts.
CVVT ASSEMBLY
1.Inspect CVVT assembly.
(1) Fix the CVVT assembly with a vice. Ensure that the cam lobe and journal is not damaged.
(2) Check that the CVVT assembly will not turn.
It should not be turned.
(3) Apply vinyl tape to the retard hole except the one(A) indicated by the arrow in the illustration.
(4)Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port of the
camshaft.
(Perform this in order to release the lock pin for the maximum delay angle locking.)
When the oil splashes, wipe it off with a shop rag.
(5) After the lock pin released, the CVVT assembly can turned in advanced direction.
If the air applied is leaked much, the lock pin can not be released.
(6) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back
and forth and check the movable range and that there is no resistance to movement.
Standard: Movable smoothly in the range about 60°
(7) Turn the CVVT assembly with your hand in retard direction and lock it at the maximum delay angle position.

Cylinder Block

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2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the drive plate(A).
2.Remove the rear plate(A).
3.Remove timing belt.
4. Remove intake manifold.
5. Remove exhaust manifold.
6. Remove generator from engine.(Refer to 'ST' group).
7. Remove power steering pump from engine.(Refer to 'HA' group).
8. Remove cylinder head.
9. Remove A/C compressor from engine.(Refer to 'EE' group).
10. Remove water pump assembly.
INSTALLATION
1.Install the water pump.
2. Install the air conditioning compressor.(Refer to 'HA' group).
3. Install the cylinder head.
4. Install the power steering pump.(Refer to 'ST' group).
5. Install the generator.
6. Install the intake manifold.
7. Install the exhaust manifold.
8. Install the timing belt.
9. Install the rear plate(A).
Tightening torque

C-
(0.0588 ~ 0.0589in.)
D GREEN 1.491 ~ 1.494mm
(0.0587 ~ 0.0588in.)
E YELLOW 1.488 ~ 1.491mm
(0.0586 ~ 0.0587in)
(11) Select the proper connecting rod bearing from the table below.
CONNECTING ROD IDENTIFICATION MARK
0(A) 1(B)2(C)
CRANKSHAFT
INDENTIFICATION MARK I(A)
E
(YELLOW) D
(GREEN) C
(-)
II(B) D
(GREEN) C
(-) B
(BLACK)
III(C) C
(-) B
(BLACK) A
(BLUE)
3. Check the connecting rod.
(1) When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new
connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
(2) If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the
rod is damaged or rough, also replace it.
(3) Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the
specification, adjust the rod with a press. If the rod is bent or twisted excessily, replace it.
Bending : 0.05mm/100mm(0.0020in./3.9370in.)
Torsion : 0.1mm/100mm(0.0039in./3.9370in.)
When assembling the rod without a bearing, there should be no difference.
4. Check the crankshaft bearing oil clearance.
(1) To check main bearing- to- journal oil clearance, remove the main bearing caps and bearing halves.
(2) Clean each main journal and bearing half with a clean shop tower.
(3) Place one strip of plastigage across each main journal.
(4) Reinstall the bearings and caps, then torque the bolts.
Tightening torque
M8 : 15.7Nm(1.6 kgf.m, 11.6lb- ft) + 90°
M10 : 29.4 Nm(3.0 kgf.m, 21.7lb- ft)+ 90°
Tighten the bolts in order.
(5) Remove the cap and bearing again, and measure the widest part of the plastigage.
Standard oil clearance
0.004~ 0.022mm (0.0002 ~ 0.0009in.)

DISCRIMINATION OF CYLINDER BLOCKCLASS MARKINSIDE DIAMETER
a A66.000 ~ 66.006mm
(2.5984 ~ 2.5987in.)
b B66.006 ~ 66.012mm
(2.5987 ~ 2.5989in.)
c C66.012 ~ 66.018mm
(2.5989 ~ 2.5991in.)
CRANKSHAFT JOURNAL MARK LOCATION
DISCRIMINATION OF CRANKSHAFT
DISCRIMINATION OF CRANKSHAFT
CLASS MARKOUTSIDE DIAMETER OF JOURNAL
I A61.994 ~ 62.000mm
(2.4407 ~ 2.4409in.)
II B61.988 ~ 61.994mm
(2.4405 ~ 2.4407in.)
III C61.982 ~ 61.988mm
(2.4402 ~ 2.4405in.)
PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)
DISCRIMINATION OF CRANKSHAFT BEARING