Kia Carnival (2009+). Instruction — part 24

Discrimination of crankshaft bearing

Color

Crankshaft bearing thickness

Black

2.013 ~ 2.018mm(0.0793~0.0794in)

Brown

2.008 ~ 2.013mm(0.0791~0.0793in)

Green

2.003 ~ 2.008mm(0.0789~0.0791in)

Yellow

1.998 ~ 2.003mm(0.0787~0.0789in)

(8) Select the bearing by using selection table.

Crankshaft main bearing selection table

Cylinder block crankshaft journal bore mark

A

None

C

Crank shaft main
journal mark

A

(Green)

(Brown)

(Black)

*

(Yellow)

(Green)

(Brown)

C

(Yellow)

(Yellow)

(Green)

5. Check the crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

End play
Standard: 0.14~ 0.39mm (0.0055 ~ 0.0154in)

If the end play is greater than maximum, replace the thrust bearings as a set.

6. Inspect the crankshaft main journals and pin journals.

Using a micrometer, measure the diameter of each main journal and pin journal.

Main journal outer diameter :
NO.1, 2, 3, 5: 69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO.3: 69.973~69.993 mm (2.7548 ~2.7556 in)
Pin journal outer diameter :
57.106 ~ 57.124mm (2.2483 ~2.2490 in)

CYLINDER BLOCK

1. Remove the gasket material.

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean the cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect the top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.

Flatness of cylinder block gasket surface Standard:
Less than 0.05mm (0.0020in)

4. Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.

5. Inspect the cylinder bore diameter.

Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :
97.100~97.126mm (3.8228~3.8239in)

6. Check the cylinder bore size code on the cylinder block bottom face.

Cylinder bore inner diameter mark location

Discrimination of cylinder bore inner diameter

Mark

Cylinder bore inner diameter

Y

101.513~101.526mm

(3.9966~3.9971in)

X

101.500~101.513mm

(3.9961~3.9966in)

Cylinder liner classifying mark location

The outer discrimination mark of the cylinder liner is on the outer surface of the liner and the inner mark is on
the top surface of it.

Discrimination of cylinder liner

Mark

Outer diameter (mm)

Mark

Inner diameter (mm)

3Y

101.493~101.506mm(3.9958~3.9963in)

Yellow

97.113~97.126mm(3.8233 ~ 3.8239in)

3Y

101.493~101.506mm(3.9958~3.9963in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Yellow

97.113~97.126mm(3.8233~3.8239in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

Piston Outer diameter mark location

Discrimination of piston outer diameter

Mark

Piston outer diameter

A

97.015~97.030mm(3.8195~3.8201in)

B

97.030~97.045mm(3.8201~3.8207in)

7. Check the piston size mark on the piston top face.

Cylinder liner selection table

Cylinder bore mark

Cylinder liner mark

Oil clearance

Y

3Y- Yellow

0.007~0.033mm(0.0003~0.0013in)

Y

3Y- Blue

0.007~0.033mm(0.0003~0.0013in)

X

3X- Yellow

0.007~0.033mm(0.0003~0.0013in)

X

3X- Blue

0.007~0.033mm(0.0003~0.0013in)

Piston

Cylinder liner mark

Piston outer

diameter mark

Oil clearance

Yellow

B

0.068~0.096mm(0.0027~0.0038in)

Blue

A

0.070~0.098mm(0.0028~0.0039in)

PISTON AND PISTON RINGS

1. Clean the piston.

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.