Kia Carnival (2009+). Instruction — part 2

Transaxle mounting bracket and body fixing
bolts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Transaxle mounting insulator and transaxle
mounting bracket fixing bolt

1

62.8 ~ 93.2

6.4 ~ 9.5

46.3 ~ 68.7

Transaxle and transaxle mounting insulator
fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Main moving system

Connecting rod cap nuts

8

68.6#Unfasten

bolts#29.4+90°

7.0 # Unfasten

bolts#3.0+ 90°

50.6# Unfasten

bolts#21.7+ 90°

Crankshaft main bearing cap bolts

10

(63.7 ~ 73.5) +

(105 + 115°)

(6.5 ~ 7.5) + (105

+ 115°)

(47.0 ~ 54.2) +

(105 + 115°)

Flywheel (DMF) bolts (M/T)

8

122.6 ~ 132.4

12.5 ~ 13.5

90.4 ~ 97.6

Drive plate bolts (A/T)

8

159.8 ~ 169.7

16.3 ~ 17.3

117.9 ~ 125.1

Timing belt

Timing belt upper cover bolts

5

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt upper cover nut

1

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt lower cover bolts

8

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Crankshaft pulley bolt

1

372.7 ~ 411.9

38.0 ~ 42.0

274.9 ~ 303.8

Camshaft sprocket bolts

2

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Timing belt tensioner bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

Timing belt N0. 1 idler bolt

1

39.2 ~ 49.0

4.0 ~ 5.0

28.9 ~ 36.2

Timing belt N0. 2 idler bolt

1

37.3 ~ 43.1

3.8 ~ 4.4

27.5 ~ 31.8

Touch idler bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

High pressure pump puli nut

1

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

High pressure pump and Timing belt case fixing
bolts

3

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Pump)

2

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Cylinder
block)

2

34.3 ~ 40.2

3.5 ~ 4.1

25.3 ~ 29.7

Timing belt plate bolts

6

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Timing belt case bolts (8 X 25)

8

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 50)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case nut

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Balancer gear bolt

1

63.7 ~ 73.5

6.5 ~ 7.5

47.0 ~ 54.2

Oil pump gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Idler gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Cylinder head

Cylinder head cover bolts

15

8.8 ~ -10.8

0.9 ~ -1.1

6.5 ~ -8.0

Rocker arm shaft And camshaft bearing cap
bolts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Camshaft bearing cap nuts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Front camshaft bearing cap nuts(Small nuts)

2

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Cylinder head bolt (Long bolts)

10

39.2 + 90° + 120°

4.0 + 90° + 120°

28.9 + 90° + 120°

Cylinder head bolt (Short bolts)

8

39.2 + 90°+ 90°

4.0 + 90° + 90°

28.9 + 90°+ 90°

Cooling system

Cooling fan water pump pulley bolts

4

5.9 ~ 9.8

0.6 ~ 1.0

4.3 ~ 7.2

Water pump bolt (Long bolts)

3

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump bolt (Short bolts)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump and generator brace fixing bolts (8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Thermostat housing and generator strip nuts

2

18.6 ~ 22.6

1.9 ~ 2.3

13.7 ~ 16.6

Thermostat case cover bolts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Lubrication system

Oil filter

1

21.6 ~ 24.5

2.2 ~ 2.5

15.9 ~ 18.1

Oil cooler bolts (8 X 35)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler bolts (8 X 50)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan nuts

29

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Ladder frame bolts (10 X 45)

5

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Ladder frame and oil suppling pipe bolt (8X 50)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Ladder frame bracket (Oil pump and ladder
frame fixing) bolts

2

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Oil supplying pipe and oil pump fixing bolts (8
X16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil supplying pipe and Ladder frame fixing bolts
(8 X 16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolts(10 X 60)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolt(8 X 30)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil screen nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pressure switch

1

14.7 ~ 46.1

1.5 ~ 2.2

10.8 ~ 34.0

Intake and exhaust system

Intake manifold and cylinder head fixing bolts(8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing bolts(8
X 95)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing
hexagonal wrench bolt

1

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and cylinder head fixing nut

9

26.5 ~ 34.3

2.7 ~ 3.5

19.5 ~ 25.3

Exhaust manifold heat cover and exhaust
manifold fixing bolts(6X12)

3

8.8 ~ 12.7

0.9 ~ 1.3

6.5 ~ 9.4

Engine hanger bracket and exhaust manifold
fixing bolts (8 X 18)

2

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and front muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Front muffler CPF(Catalyzed Particulate Filter)
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

CPF(Catalyzed Particulate Filter) main muffler
fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

Main muffler and tail pipe fixing nuts

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4

2009 > D 2.9 VGT >

INSPECTION

COMPESSION PRESSURE

If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up the engine until the coolant temperature becomes 80~95°C(176~203°F).

2. Remove the fuel inlet(A) and the return hose(B) from the fuel filter.

3. Crank the engine in order to exhaust fuel in the high pressure pump.

Gather residual fuel by putting the return hose into a proper vessel.

4. Remove the injection pipe, injector and washer.(Refer to FL group).

5. Measure the cylinder compression pressure.

(1) Insert the SST(0K552 131 002) into the injector hole.

(2) Cranking the engine, measure the pressure.

Use the complete charging battery for the engine to crank at the speed of 350rpm or more.

(3) Do the above step 1)~2) again for each cylinder.

This work must be done in as short time as possible.

Compression pressure :
3040.05kPa (31kg/cm!, 440.92psi) (325 rpm)
Minimum pressure :
2745.85kPa (28kg/cm!, 398.25psi)
Difference between each cylinder :
294.20kPa (3.0kg/cm!, 42.67psi)

(4) If, in one or more cylinders, the measured value is below the limit, fill a little engine oil into the injector holes of

the cylinders, repeat the step 1)~2) and measure the compression pressure again.

A. If the re-measured pressure becomes higher, wear or damage of the piston ring or cylinder surface can be

the cause.

B. If the re-measured pressure does not become higher, adherence or poor contact of the valves or inferior

gasket can be the cause.