Kia Carnival (2007 year). Instruction — part 417

(2) Clean each main journal and lower bearing with a clean shop towel.

(3) Place one strip of plastigage across each main journal.

(4) Reinstall the lower bearings and caps, then tighten the bolts.

Tightening torque :
69.6~79.4Nm(7.1~8.1kgf.m, 51.4~58.6lb-ft)+55°~ 65°

Do not turn the crankshaft.

(5) Remove the cap and lower bearing again, and measure the widest part of the plastigage.

Standard oil clearance :
No.1, 2, 3, 5: 0.045~0.079mm (0.0018 ~0.0031 in)
No.3: 0.067~0.101 mm (0.0026 ~0.0040 in)

(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new

bearings with the same color mark. (Refer to crankshaft main bearing selection table).
Recheck the oil clearance.

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

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft

main bearing selection table).
Recheck the oil clearance.

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.

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.

Discrimination of cylinder block crankshaft journal bore

Mark

Cylinder block crankshaft journal bore inner diameter

A

74.066~74.075mm

(2.9160~2.9163in)

None

74.075~74.084mm

(2.9163~2.9167in)

C

74.084~74.092mm

(2.9167~2.9170in)

Crankshaft main journal mark location

Discrimination of crankshaft main journal

Mark

Crankshaft main journalouter diameter

No.1, 2, 3, 5 journal

No.3 journal

1

69.995~70.002mm(2.7557~2.7560in)

69.973~69.980mm(2.7548~2.7551in)

*

70.002~70.009mm(2.7560~2.7563in)

69.980~69.987mm(2.7551~2.7554in)

3

70.009~70.015mm(2.7563~2.7565in)

69.987~69.993mm(2.7554~2.7556in)

Crankshaft main bearing mark location

Discrimination of crankshaft bearing

Color

Crankshaft bearing thickness

Black

2.013 ~ 2.018mm(0.0793~0.0794in)

Brown

2.008 ~ 2.013mm(0.0791~0.0793in)

Green

2.003 ~ 2.008mm(0.0789~0.0791in)

Yellow

1.998 ~ 2.003mm(0.0787~0.0789in)

(8) Select the bearing by using selection table.

Crankshaft main bearing selection table

Cylinder block crankshaft journal bore mark

A

None

C

Crank shaft main
journal mark

A

(Green)

(Brown)

(Black)

*

(Yellow)

(Green)

(Brown)

C

(Yellow)

(Yellow)

(Green)

5. Check the crankshaft end play.

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

End play
Standard: 0.14~ 0.39mm (0.0055 ~ 0.0154in)

If the end play is greater than maximum, replace the thrust bearings as a set.

6. Inspect the crankshaft main journals and pin journals.

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

Main journal outer diameter :
NO.1, 2, 3, 5: 69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO.3: 69.973~69.993 mm (2.7548 ~2.7556 in)
Pin journal outer diameter :
57.106 ~ 57.124mm (2.2483 ~2.2490 in)

CYLINDER BLOCK

1. Remove the gasket material.

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

2. Clean the 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:
Less than 0.05mm (0.0020in)

4. Inspect the cylinder bore.

Visually check the cylinder for vertical scratchs.
If deep scratchs are present, replace the cylinder block.

5. Inspect the cylinder bore diameter.

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

Standard diameter :
97.100~97.126mm (3.8228~3.8239in)