Kia Carnival (2007 year). Instruction — part 416

17. Check the connecting rod end play.

18. Remove the connecting rod caps and check oil clearance.

19. Remove the piston and connecting rod assemblies.

(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.

(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

a. Keep the bearings, connecting rod and cap together.
b. Arrange the piston and connecting rod assemblies in the correct order.

20. Remove the rear oil seal case.

Remove the 5 bolts(B) and the rear oil seal case(A).

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

22. Check the crankshaft end play.

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

Arrange the main bearings and thrust bearings in the correct order.

24. Check fit between piston and piston pin.

25. Remove the piston rings.

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

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

Arrange the piston rings in the correct order only.

26. Remove the connecting rod from the piston.

Using a press, remove the piston pin from piston.

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using feeler gauge, measure the end play while moving the connecting rod back and forth.

End play
0.239 ~ 0.39mm (0.0094 ~ 0.0154in)

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

(2) Remove the 2 connecting rod cap nuts.

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

(4) Clean the crankshaft pin journal and bearing.

(5) Place a plastigage across the crankshaft pin journal.

(6) Reinstall the lower bearing and cap, and tighten the nuts.

Tightening torque :
68.6Nm (7.0 kgf.m, 50.6lb-ft) → Unfasten bolts→29.4Nm (3.0kgf.m, 21.7lb-ft) + 90°

Do not turn the crankshaft.

(7) Remove the 2nuts, connecting rod cap and lower bearing .

(8) Measure the plastigage at its widest point.

Standard oil clearance
0.043 ~ 0.077mm (0.0017 ~ 0.0030in)

(9) 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 connecting rod bearing selection table)
Recheck the oil clearance.

Do not file, shim, of 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. ( Refer to

connecting rod 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.

Connecting rod mark location

Discrimination of connecting rod

Mark

Connecting rod big-endinner diameter

1

60.833 ~ 60.839mm

(2.3950 ~ 2.3952 in)

2

60.839 ~ 60.846mm

(2.3952 ~ 2.3955 in)

CRANKSHAFT PIN JOURNAL

Journal outer diameter
57.106~57.124mm (2.2483~2.2490in)

CONNECTING ROD BEARING MARK LOCATION

Discrimination of crankshaft pin journal

Color

Connecting rod bearing thickness

Blue

1.0828~1.832mm

(0.0720~0.0721in)

Red

1.832~1.836mm

(0.0721~0.0723in)

(11) Select the bearing by using the selection table.

Connecting rod bearing selection table

Connecting rod mark

Connecting rod bearing thickness

Oil clearance

1

Blue

0.045~0.077mm(0.0018~0.0030in)

2

Red

0.043~0.076mm(0.0017~0.0030in)

3. Check the connecting rods.

(1) When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match.

When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the
same side.

(2) Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely

rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.

(3) Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the

repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be
replaced.

Allowable bend of connecting rod :
0.04mm / 50mm (0.0016in / 1.9685in ) or less
Allowable twist of connecting rod :
0.1mm / 50mm (0.0039in / 1.9685in) or less

4. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.