Kia Carnival (2007 year). Instruction — part 409

DISASSEMBLY

1. Remove the valves.

(1) Using the SST (0K9993 120 004, 0K993 120 001), compress the valve spring and remove the retainer lock.

(2) Remove the spring retainer.

(3) Remove the valve spring.

(4) Remove the valve.

(5) Using a needle-nose pliers, remove the oil seal.

(6) Using a magnetic finger, remove the spring seat.

INSPECTION

CYLINDER HEAD

1. Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.

Flatness of cylinder head gasket surface
Less than 0.05mm (0.0020in)
Flatness of manifold mating surface
Less than 0.15mm (0.0059in)

2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.

VALVE AND VALVE SPRING

1. Inspect the valve stems and valve guides.

(1) Using a caliper gauge, measure the innner diameter of valve guide.

Valve guide inner diameter :
7.010~7.030mm (0.2760~0.2768in)

(2) Using a micrometer, measure the outer diameter of valve stem.

Valve stem outer diameter
Intake : 6.965~6.980mm (0.2742~0.2748in)
Exhaust : 6.945~6.960mm (0.2734~0.2740in)

(3) Subtract the valve stem outer diameter measurement from the valve guide innner diameter measurement.

Valve stem- to-guide clearance
Intake : 0.030 ~ 0.065mm (0.0012 ~ 0.0026in)
Exhaust : 0.050 ~ 0.085mm (0.0020 ~ 0.0033in)

If the clearance is greater than maximum, replace the valve and valve guide.

2. Inspect the valves.

(1) Check the valve is ground to the correct valve face angle.

(2) Check that the surface of valve for wear.

If the valve face is worn, replace the valve.

(3) Check the valve head margin thickness.

If the margin thickness is less than minimum, replace the valve.

Margin
Intake : 1.7mm (0.0669in)
Exhaust : 1.6mm (0.0630in)

(4) Check the surface of valve stem tip for wear.

If the valve stem tip is worn, replace the valve.

3. Inspect the valve seats.

(1) Check the valve seat for evidence of overheating and improper contact with the valve face.

Replace the seat if necessary.

(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then

recondition the seat.

(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within

4. Inspect the valve springs.

(1) Using a steel square, measure the out-of-square of valve spring.

(2) Using a vernier calipers, measure the free length of valve spring.

Valve spring
Free height : 52.477mm (2.0660in)
Installed load: 51.7±4.1kg/40.0mm(41.4±2.0lb/1.5748in)
Compressed load:86.3±6.9kg/31.65mm(41.4±2.0lb/1.2461in) (Intake)
86.9±6.9kg/31.50mm(41.4±2.0lb/1.2402in) (Exhaust)
Out of square : Less than 2°

If the loads is not as specified, replace the valve spring.

CAMSHAFT

1. Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

Cam height
Intake : 39.397~39.597mm (1.5511~1.5589in)
Exhaust : 39.4932~39.6932mm (1.5548~1.5627in)

If the cam lobe height is less than minimum, replace the camshaft.

2. Inspect the camshaft journal clearance.

(1) Clean the bearing caps and camshaft journals.

(2) Place the camshafts on the cylinder head.

(3) Lay a strip of plastigage across each of the camshaft journal.

(4) Install the bearing caps and tighten the bolts with specified torque.

Do not turn the camshaft.