Kia Carnival (2009+). Instruction — part 201

6. Check the connecting rod side clearance.

7. Check the connecting rod bearing oil clearance.

8. Remove the piston and connecting rod assemblies.

• Keep the bearings the connecting rods and the caps together.
• Arrange the piston and connecting rod assemblies in the correct order.

9. Remove the oil pump case.

10. Remove the oil seal case(A).

11. Check the crankshaft end play.

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

Arrange the bearings and the bearing caps in order.

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

14. Remove and arrange the main bearings and thrust bearings in the correct order.

15. Remove the CKP sensor(A).

16. Check the free play between a piston and a piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston
pin as a set.

17. Remove the piston rings.

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

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

Arrange the piston rings in the correct order only.

18. Disconnect the connecting rod from the piston.

Using a press, remove the piston pin from the piston.
(Press-in load : 2451.7 ~ 12258.3N(250 ~ 1250kg, 551.2 ~ 2755.81lb)

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod side clearance.

Using a feeler gauge, measure the side clearance while moving the connecting rod back and forth.

Specification
Standard : 0.1~ 0.25mm(0.0039 ~ 0.0098in.)
Limit : 0.4mm(0.0157in.)

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

(2) Remove the 2 connecting rod cap bolts.

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

(4) Clean the crankshaft pin journal and the bearing.

(5) Place a plastigage across the crankshaft pin.

(6) Reinstall the lower bearing and the connecting rod cap and torque the bolts.

Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 90~94°

Do not turn the crankshaft.

Always use new connecting rod cap bolts.

(7) Remove the connecting rod cap again.

(8) Measure the plastigage at its widest point.

Standard oil clearance
0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,

complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed

above or below that one), and check clearance again.

If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace
the crankshaft and start over.

If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent or detergent.

CONNECTING ROD MARK LOCATION

DISCRIMINATION OF CONNECTING ROD

CLASS

MARK

INSIDE DIAMETER

0

a

51.000 ~ 51.006mm

(2.0079 ~ 2.0081in.)