2007 KIA CARNIVAL oil

The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of
the radiator support upper member assembly.
18.Drain engine oil.
19. Remove the brake caliper.(Refer to DS group).
20. Disconnect the air conditioning compressor hoses.(Refer to HA group).
21. Remove the front wheels and tires.(Refer to DS group).
22. Remove the brake caliper hub nut.(Refer to DS group).
23. Remove the tie rod end ball joint from the knuckle.(Refer to DS group)
24. Remove the driver shaft and the stabilizer bar link(Refer to SS group).
25. Remove the front muffler(A).
26.Using a floor jack, support the engine and transaxle assembly.
After removing the sub frame mounting bolt , the engine and transaxle assembly may fall downward, and so
support them securely with floor jack.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following :a. Adjust the shift cable.
b. Refill the engine with engine oil.
c. Refill the transaxle with fluid.
d. Refill the radiator with engine coolant.
e. Bleed air from the cooling system with the heater valve open.
f. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent
corrosion.
g. Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

3.Remove the lower oil pan(A).
4.Remove the oil screen(A).
5.Remove the upper oil pan(A).
When removing the oil pan, use the SST(09215- 3C000) not to damage the contacting surface of the oil pan.

6.Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.
a.Keep the bearings the connecting rods and the caps together.
b. Arrange the piston and connecting rod assemblies in the correct order.
9. Remove the oil pump case.
10. Remove the oil seal case(A).
11.Check the crankshaft end play.
12. Remove the crankshaft bearing cap and check oil clearance.
Arrange the bearings and the bearing caps in order.
13. Lift the crankshaft(A) out of the block, being careful not to damage journals.

14.Remove and arrange the main bearings and thrust bearings in the correct order.
15.Remove the CKP sensor(A).
16.Check the free play between a piston and a piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston
pin as a set.
17. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove the 2 side rails and the oil ring by hand.

Arrange the piston rings in the correct order only.
18. Disconnect the connecting rod from the piston.
Using a press, remove the piston pin from the piston.
(Press- in load : 2451.7 ~ 12258.3N(250 ~ 1250kg, 551.2 ~ 2755.81lb)
INSPECTION
CONNECTING ROD AND CRANKSHAFT
1. Check the connecting rod side clearance.
Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.
Specification
Standard : 0.1~ 0.25mm(0.0039 ~ 0.0098in.)
Limit : 0.4mm(0.0157in.)
a.If out - of- tolerance, install a new connecting rod.
b. If still out - of- tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance.
(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
(2) Remove the 2 connecting rod cap bolts.
(3) Remove the connecting rod cap and the lower bearing.
(4) Clean the crankshaft pin journal and the bearing.
(5) Place a plastigage across the crankshaft pin.
(6) Reinstall the lower bearing and the connecting rod cap and torque the bolts.
Tightening torque
19.6Nm (2.0kgf.m, 14.46lb- ft) + 90°
Do not turn the crankshaft.
(7) Remove the connecting rod cap again.
(8) Measure the plastigage at its widest point.
Standard oil clearance
0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)

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.)

Standard diameter
86.67 ~ 87.00(3.4122 ~ 3.4252in.)
3.Calculate the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston - to- cylinder clearance
0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
4. Inspect the piston ring side clearance.
Using a feeler gauge, measure the clearance between a new piston ring and the ring groove.
Piston ring side clearance
Standard
No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)
If the clearance is greater than the maximum, replace the piston.
5. Inspect piston ring end gap.
To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is
over the service limit, the cylinder block must be replaced or bored
Piston ring end gap
Standard
No.1 : 0.15 ~ 0.30mm (0.0059 ~ 0.0118in.)
No.2 : 0.30 ~ 0.45m (0.0118 ~ 0.0177in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit