Kia Carnival (2007 year). Instruction — part 544

Out-of-square : 1.5°

MLA

1. Inspect MLA.

Using a micrometer, measure the MLA outside diameter.

MLA O.D.
Intake/Exhaust : 34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)

2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.

Tappet bore I.D.
Intake/Exhaust : 35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)

3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.

MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)

CAMSHAFT

1. Inspect cam lobes.

Using a micrometer, measure the cam lobe height.

Cam height
[Standard value]
Intake : 46.8mm (1.8425in.)
Exhaust : 45.8mm (1.8031in.)

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

2. Inspect 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.

Do not turn the camshaft.

(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.

Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

(7) Completely remove the plastigage.

(8) Remove the camshafts.

3. Inspect camshaft end play.

(1) Install the camshafts.

(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play
[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

(3) Remove the camshafts.

CVVT ASSEMBLY

1. Inspect CVVT assembly.

(1) Check that the CVVT assembly will not turn.

(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.

(3) Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port of the

camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)

When the oil splashes, wipe it off with a shop rag.

(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in

the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by
hand. Also, If excessive air leaks from the port, the lock pin may not be fully released.

(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back

and forth and check the movable range and that there is no resistance to movement.

Standard: Movable smoothly in the range about 22.5°

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (counter clockwise).

REASSEMBLY

Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

1. Install valves.

(1) Using SST(09222-3C100), push in a new oil seal.

Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.

(2) Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then
installs the retainer.

(3) Using the SST(09222 - 3K000, 09222-3C300), compress the spring and install the retainer locks. After

installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring
compressor.