Kia Carnival (2009+). Instruction — part 22

9. Remove the A/C compressor bracket(A).

10. M/T : remove flywheel.

11. A/T : remove drive plate and mass wheel.

12. Using the SST(09215 - 3C000) remove the oil pan(A).

13. Remove the oil pump feed pipe(A) and the ladder frame bracket(B).

14. Remove the ladder frame(A) and the oil pump assembly(B).

15. Remove the balancer shaft(A) to the ladder frame.

(1) Remove the gear cover(A) to the ladder frame.

(2) Remove the balancer sprocket and the balancer gear by loosening the bolts(B).

Not to make the balance shaft be rotated, insert the 5mm-thickeness urethane rubber (B) in the balance
gear (A) for protection.

(3) Remove the thrust plate and the balance shaft.

16. Remove the timing belt case(A).

17. Check the connecting rod end play.

18. Remove the connecting rod caps and check oil clearance.

19. Remove the piston and connecting rod assemblies.

(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

• Keep the bearings, connecting rod and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.

20. Remove the rear oil seal case.

Remove the 5 bolts(B) and the rear oil seal case(A).

21. Remove the crankshaft bearing cap and check oil clearance.

22. Check the crankshaft end play.

23. Lift the crankshaft(A) out of the engine, being careful not to damage journals.

Arrange the main bearings and thrust bearings in the correct order.

24. Check fit between piston and piston pin.

25. Remove the piston rings.

(1) Using a piston ring expender, remove the 2 compression rings.

(2) Remove the 2 side rails and oil ring by hand.

Arrange the piston rings in the correct order only.

26. Remove the connecting rod from the piston.

Using a press, remove the piston pin from piston.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using feeler gauge, measure the end play while moving the connecting rod back and forth.

End play
0.239 ~ 0.39mm (0.0094 ~ 0.0154in)

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 match marks on the connecting rod and cap are aligned to ensure correct reassembly.

(2) Remove the 2 connecting rod cap nuts.

(3) Remove the connecting rod cap and lower bearing.

(4) Clean the crankshaft pin journal and bearing.

(5) Place a plastigage across the crankshaft pin journal.

(6) Reinstall the lower bearing and cap, and tighten the nuts.

Tightening torque :
68.6Nm (7.0 kgf.m, 50.6lb-ft) ! Unfasten bolts!29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Do not turn the crankshaft.

(7) Remove the 2nuts, connecting rod cap and lower bearing .