Kia Carnival (2009+). Instruction — part 203

PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)

DISCRIMINATION OF CRANKSHAFT BEARING

CLASS

MARK

THICKNESS OF BEARING

A

BLUE

2.007 ~ 2.010mm

(0.0790 ~ 0.0791in.)

B

BLACK

2.004 ~ 2.007mm

(0.0789 ~ 0.0790in.)

C

-

2.001 ~ 2.004mm

(0.0788 ~ 0.0789in.)

D

GREEN

1.998 ~ 2.001mm

(0.0787 ~ 0.0788in.)

E

YELLOW

1.995 ~ 1.998mm

(0.0785 ~ 0.0787in.)

SELECTION TABLE

CRANKSHAFT BORE IDENTIFICATION MARK

a(A)

b(B)

c(C)

CRANKSHAFT

IDENTIFICATION MARK

I(A)

E

(YELLOW)

D

(GREEN)

C

(-)

II(B)

D

(GREEN)

C

(-)

B

(BLACK)

III(C)

C

(-)

B

(BLACK)

A

(BLUE)

5. Check crankshaft end play.

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

Standard end play
0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
[Limit]
0.3mm(0.0118in.)

If the end play is greater than the maximum, replace the center bearing.

Thrust bearing thickness
1.925 ~ 1.965mm(0.0758 ~ 0.0774in.)
Standard end play
0.07 ~ 0.25mm (0.0028 ~ 0.0098in.)
[Limit]
0.3mm(0.0118in.)

6. Inspect the main journals and the pin journals of the crankshaft.

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

Main journal diameter : 61.982~ 62.000mm (2.4402 ~ 2.4409in.)
Crank pin diameter : 47.982 ~ 48.000mm (1.8891 ~ 1.8898in.)

CYLINDER BLOCK

1. Remove gasket materials.

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

2. Clean 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 : 0.03mm(0.0012in.) or less

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block or process the piston to be oversized.

5. Inspect the cylinder bore diameter

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

Standard diameter
86.70 ~ 86.73mm (3.4134 ~ 3.4146in.)

6. Check the cylinder bore size code(A) on the cylinder block.

Class

Size code

Cylinder bore inner diameter

A

A

86.70 ~ 86.71mm

(3.4134 ~ 3.4138in.)

B

B

86.71 ~ 86.72mm

(3.4138 ~ 3.4142in.)

C

C

86.72 ~ 86.73mm

(3.4142 ~ 3.4146in.)

7. Check the piston size code(A) on the piston top face.

Class

Size code

Piston outer diameter

A

A

86.67 ~ 86.68mm

(3.4122 ~ 3.4126in.)

B

-

86.68 ~ 86.69mm

(3.4126 ~ 3.4130in.)

C

C

86.69 ~ 86.70mm

(3.4130 ~ 3.4134in.)

8. Select the proper piston related to the cylinder bore class.

Clearance : 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)

CYLINDER BORING

1. The over size piston is chosen on the maximum inner diameter of the cylinder.