Kia Carnival (2009+). Instruction — part 26

3. Install the connecting rod bearings.

(1) Align the bearing (A) claw with the groove of the connecting rod and bearing cap (B).

(2) Install the bearings (A) in the connecting rod and bearing cap (B).

4. Install the crankshaft main bearings.

Upper bearings have oil grooves of the oil holes; Lower bearings do not.

(1) Aligning the bearing protrusions with the grooves of the cylinder block, push in the 5 upper bearings (A).

(2) Aligning the bearing protrusions with the grooves of the main bearing cap, and push in the 5 lower bearings.

5. Install the thrust bearings.

Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

6. Place the crankshaft on the cylinder block.

7. Place the main bearing caps on the cylinder block.

8. Install the main bearing cap bolts.

• The main bearing cap bolts are tightened in 2 progressive steps.
• Always use new main bearing cap bolts.

(1) Apply a light coat of engine oil on the threads of the main bearing cap bolts.

(2) Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.

Tightening torque :
63.7~73.5Nm(6.5~7.5kgf.m, 47.0~54.2lb-ft)+105°~115°

(3) Check that the crankshaft turns smoothly.

9. Check the crankshaft end play.

10. Install the piston and connecting rod assemblies.

• Before installing the piston, apply a coat of engine oil to the piston ring grooves and the cylinder bores.
• When installing the piston pin to the piston, apply engine oil sufficiently

(1) Remove the connecting rod bearing caps and insert short sections of rubber hose over the threaded ends of

the connecting rod bolts.

(2) Install the ring compressor, checking that the rings are securely in place and positioning the piston in the

cylinder, tap it in using the wooden handle of a hammer.

(3) Stop inserting after the ring inserted in the cylinder, and check the connecting rod to crank journal alignment

before complete inserting.

(4) Apply engine oil to the bolt threads after removing rubber hose. Install the connecting rod caps with bearings,

and tighten the nuts.

and tighten the nuts.

Tightening torque :
68.9Nm (7.0kgf.m, 50.6lb-ft) ! Loosened !29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Maintain downward force on the ring compressor to prevent the rings from expending before entering the
cylinder bore.

11. Install a new gasket and rear oil seal case(A) with 5 bolts(B).

Tightening torque :
7.8 ~ 10.8Nm (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft)

Check that the mating surfaces are clean and dry.

12. Install the rear oil seal.

(1) Apply engine oil to a new oil seal lip.

(2) Tap in the rear oil seal until its surface is flush with the rear oil seal retainer edge.

13. Install the balance shaft to the ladder frame.

(1) Install the thrust plate and balance shaft to the ladder frame.

(2) Aligning the timing marks on the balance gear(A), install the balance sprocket.

(3) Tighten the balance sprocket bolt and balance gear bolt(C).

Tightening torque :
Rear balance gear bolt(C)-
37.3 ~ 52.0Nm (3.8 ~ 5.3kgf.m, 27.5 ~ 38.3lb-ft)
Front balance gear bolt-
63.7 ~ 73.5Nm (6.5 ~ 7.5kgf.m, 47.0 ~ 54.2lb-ft)

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

(4) Install the gear cover (A) to the ladder frame and tighten the bolts (B).

Tightening torque :
18.6 ~ 25.5Nm (1.9 ~ 2.6kgf.m, 13.7 ~ 18.8lb-ft)

14. Install the oil screen with a new gasket to the oil pump.