Kia Carnival (2007 year). Instruction — part 399

Width of seat contact

Intake

1.4 ~ 2.0mm (0.0551 ~ 0.0787in)

Exhaust

0.9 ~ 1.5mm (0.0354 ~0.0591 in)

Seat angle

45°

Valve spring

Free length

52.477mm (2.0660in)

Load(Intake)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.15±3.13kg/31.65mm(86.3±6.9 lb/1.2461 in)

Load(Exhaust)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.43±3.15kg/31.50mm(86.9±6.9 lb/1.2402 in)

Out of squareness

Less than 2°

3°

Rocker arm and rocker arm shaft

Rocker arm inner diameter

20.000 ~ 20.027mm (0.7874 ~ 0.7885in)

Rocker arm shaft outer diameter

19.959 ~ 19.980mm (0.7858 ~ 0.7866in)

Cylinder block

Cylinder bore

101.500 ~ 101.526mm (3.9961 ~3.9971 in)

Liner inner diameter

97.100 ~ 97.126mm (3.8228~ 3.8239in)

Liner outer diameter

101.480 ~ 101.526mm ( 3.9953~ 3.9971in)

Flatness of gasket surface

Less than 0.05mm (0.0020in)

Piston

Piston outer diameter

97.015 ~ 97.030mm ( 3.8195~ 3.8201in)

Piston to cylinder clearance

0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

Ring groove width

No. 1 ring groove

2.397 ~ 2.417mm ( 0.0944~0.0952 in)

No. 2 ring groove

2.05 ~ 2.07mm ( 0.0807~ 0.0815in)

Oil ring groove

3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

Piston ring

Side clearance

No. 2 ring

0.06 ~ 0.10mm (0.0024~0.0039 in)

Oil ring

0.03 ~ 0.07mm (0.0012~0.0028 in)

End gap

No. 1 ring

0.25 ~ 0.40mm (0.0098~ 0.0157in)

No. 2 ring

0.40 ~ 0.55mm (0.0157~0.0217in)

Oil ring

0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston pin

Piston pin outer diameter

31.994 ~ 32.000mm (1.2596 ~ 1.2598 in)

Piston pin hole inner diameter

32.015 ~ 32.025mm (1.2604 ~ 1.2608 in)

Piston pin hole clearance

0.015 ~ 0.031mm (0.0006 ~ 0.0012 in)

Connecting rod small end inner diameter

32.012 ~ 32.033mm (1.2603 ~ 1.2611 in)

Connecting rod small end hole clearance

0.012 ~ -0.039mm (0.0005 ~ 0.0015 in)

Connecting rod

Connecting rod big end inner diameter

60.833 ~ 60.846mm (2.3950 ~ 2.3955 in)

Connecting rod bearing oil clearance

0.043 ~ 0.077mm (0.0017 ~ 0.0030 in)

End play

0.239~0.39 (0.0094 ~ 0.0154 in)

Crankshaft

Main journal outer
diameter

NO 1, 2, 4, 5

69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO 3

69.973~69.993mm (2.7548 ~2.7556 in)

Pin journal outer diameter

57.106~57.124mm (2.2483~2.2490 in)

Main bearing oil
clearance

NO 1, 2, 4, 5

0.045 ~ 0.079mm (0.0018 ~0.0031 in)

NO 3

0.067~0.101 mm (0.0026 ~0.0040 in)

End play

0.14 ~ 0.39mm (0.0055 ~0.0154 in)

Flywheel

Runout

0.10mm (0.0039in)

0.13mm (0.0051in)

Oil pump

Relief valve opening pressure

588.40±49.0kpa(6.0±0.5kg/cm²,85.34±7.1psi)

Discharge volume

75L/min(79.25 US qt/min, 65.99 lmp qt/min)
(engine3,800rpm)

Engine oil

Oil quantity (Total)

8.0 L (8.45 US qt, 7.03 lmp qt)

Oil quantity (Oil pan)

6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Drain and refill including oil filter) 6.6 L (6.97 US qt, 5.08 lmp qt)

Oil quality

ABOVE API CH-4 or ABOVE ACEA B4

Oil pressure (Idle)

78.45 kpa (0.8 kg/cm², 11.38 psi)

Cooling system

Cooling method

Forced circulation with cooling fan

Thermostat

Type

Wax pellet type

Opening temperature

88±1.5 °C (190.4 ±34.7 °F)

Pull opening
temperature

100 °C (212.0 °F)

Radiator cap

Main valve opening
pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51
~ 17.78psi)

Water temperature sensor

Type

Thermister type

Resistance

20°C (68°F)

2.27~2.64 kΩ

80°C (176°F)

0.31~0.33 kΩ

TIGHTENING TORQUE

Item

Quan-

tity

Tightening torque

N.m

kgf.m

lb-ft

Cylinder block

Engine support bracket bolts

8

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine mounting

Engine mounting insulator and engine mounting
bracket fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine support bracket and engine mounting
insulator fixing nuts

2

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Transaxle mounting bracket and body fixing
bolts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Transaxle mounting insulator and transaxle
mounting bracket fixing bolt

1

62.8 ~ 93.2

6.4 ~ 9.5

46.3 ~ 68.7

Transaxle and transaxle mounting insulator
fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Main moving system

Connecting rod cap nuts

8

68.6→Unfasten

bolts→29.4+90°

7.0 → Unfasten

bolts→3.0+ 90°

50.6→ Unfasten

bolts→21.7+ 90°

Crankshaft main bearing cap bolts

10

69.6~79.4+55°~65°

7.1 ~

8.1+55°~65°

51.4~58.6+55°~65°

Flywheel (DMF) bolts (M/T)

8

122.6 ~ 132.4

12.5 ~ 13.5

90.4 ~ 97.6

Drive plate bolts (A/T)

8

159.8 ~ 169.7

16.3 ~ 17.3

117.9 ~ 125.1

Timing belt

Timing belt upper cover bolts

5

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt upper cover nut

1

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt lower cover bolts

8

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Crankshaft pulley bolt

1

372.7 ~ 411.9

38.0 ~ 42.0

274.9 ~ 303.8

Camshaft sprocket bolts

2

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Timing belt tensioner bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

Timing belt N0. 1 idler bolt

1

39.2 ~ 49.0

4.0 ~ 5.0

28.9 ~ 36.2

Timing belt N0. 2 idler bolt

1

37.3 ~ 43.1

3.8 ~ 4.4

27.5 ~ 31.8

Touch idler bolt

1

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

High pressure pump puli nut

1

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

High pressure pump and Timing belt case fixing
bolts

3

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Pump)

2

21.6 ~ 25.5

2.2 ~ 2.6

15.9 ~ 18.8

High pressure pump bracket bolts (Cylinder
block)

2

34.3 ~ 40.2

3.5 ~ 4.1

25.3 ~ 29.7

Timing belt plate bolts

6

6.9 ~ 9.8

0.7 ~ 1.0

5.1 ~ 7.2

Timing belt case bolts (8 X 25)

8

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case bolts (8 X 50)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Timing belt case nut

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Balancer gear bolt

1

63.7 ~ 73.5

6.5 ~ 7.5

47.0 ~ 54.2

Oil pump gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Idler gear bolt

1

33.3 ~ 39.2

3.4 ~ 4.0

24.6 ~ 28.9

Cylinder head

Cylinder head cover bolts

15

8.8 ~ -10.8

0.9 ~ -1.1

6.5 ~ -8.0

Rocker arm shaft And camshaft bearing cap
bolts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Camshaft bearing cap nuts

10

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Front camshaft bearing cap nuts(Small nuts)

2

7.8 ~ 11.8

0.8 ~ 1.2

5.8 ~ 8.7

Cylinder head bolt (Long bolts)

10

39.2 + 90° + 120°

4.0 + 90° + 120°

28.9 + 90° + 120°

Cylinder head bolt (Short bolts)

8

39.2 + 90°+ 90°

4.0 + 90° + 90°

28.9 + 90°+ 90°

Cooling system

Cooling fan water pump pulley bolts

4

5.9 ~ 9.8

0.6 ~ 1.0

4.3 ~ 7.2

Water pump bolt (Long bolts)

3

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump bolt (Short bolts)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Water pump and generator brace fixing bolts (8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Thermostat housing and generator strip nuts

2

18.6 ~ 22.6

1.9 ~ 2.3

13.7 ~ 16.6

Thermostat case cover bolts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Lubrication system

Oil filter

1

21.6 ~ 24.5

2.2 ~ 2.5

15.9 ~ 18.1

Oil cooler bolts (8 X 35)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler bolts (8 X 50)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil cooler nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan nuts

29

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pan drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Ladder frame bolts (10 X 45)

5

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Ladder frame and oil suppling pipe bolt (8X 50)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Ladder frame bracket (Oil pump and ladder
frame fixing) bolts

2

31.4 ~ 46.1

3.2 ~ 4.7

23.1 ~ 34.0

Oil supplying pipe and oil pump fixing bolts (8
X16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil supplying pipe and Ladder frame fixing bolts
(8 X 16)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolts(10 X 60)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pump bolt(8 X 30)

1

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil screen nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Oil pressure switch

1

14.7 ~ 46.1

1.5 ~ 2.2

10.8 ~ 34.0

Intake and exhaust system

Intake manifold and cylinder head fixing bolts(8
X 45)

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing bolts(8
X 95)

4

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing nuts

2

15.7 ~ 22.6

1.6 ~ 2.3

11.6 ~ 16.6

Intake manifold and cylinder head fixing
hexagonal wrench bolt

1

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and cylinder head fixing nut

9

26.5 ~ 34.3

2.7 ~ 3.5

19.5 ~ 25.3

Exhaust manifold heat cover and exhaust
manifold fixing bolts(6X12)

3

8.8 ~ 12.7

0.9 ~ 1.3

6.5 ~ 9.4

Engine hanger bracket and exhaust manifold
fixing bolts (8 X 18)

2

17.7 ~ 26.5

1.8 ~ 2.7

13.0 ~ 19.5

Exhaust manifold and front muffler fixing nut

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4