Kia Carnival (2007 year). Manual — part 5

Valve stem to valve
guide clearance

Intake

0.020 ~ 0.050mm(0.0008 ~ 0.0020in.)

0.10mm(0.0039in.)
or less

Exhaust

0.035 ~ 0.065mm(0.0014 ~ 0.0026in.)

0.13mm(0.0051in.)
or less

Valve guide

Inner diameter

Intake

6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)

Exhaust

6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)

Length

Intake

45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)

Exhaust

46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)

Valve spring

Free length

46.8mm(1.8425in.)

Load

Height: 35mm

180.5 ~ 199.5N(18.4 ~ 20.3Kgf, 40.6 ~ 44.8lb)

Height: 26.5mm

342 ~ 378N(34.9 ~ 38.6Kgf, 76.9 ~ 85.1lb)

Out of squareness

1.5° or less

MLA(Mechanical Lash Adjuster)

MLA outer diameter Intake

29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)

Exhaust

29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)

Cylinder head
tappet bore inner
diameter

Intake

30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)

Exhaust

30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)

MLA to tappet bore
clearance

Intake

0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)

0.07mm(0.0027in.)
or less

Exhaust

0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)

0.07mm(0.0027in.)
or less

Valve clearance

Intake

0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)

0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)

Exhaust

0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)

Cylinder block

Cylinder bore

96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)

Flatness of gasket surface

Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]

Piston

Piston outer diameter

95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)

Piston to cylinder clearance

0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

Ring groove width

No. 1 ring groove

1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)

No. 2 ring groove

1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)

Oil ring groove

2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)

Piston O.S.

0.25mm(0.0098in.)

Piston ring

Side clearance

No. 1 ring

0.04 ~ 0.08mm(0.0016 ~ 0.0031in.)

0.1mm(0.0039in.)

No. 2 ring

0.03 ~ 0.07mm(0.0012 ~ 0.0027in.)

0.1mm(0.0039in.)

Oil ring

0.06 ~ 0.15mm(0.0024 ~ 0.0059in.)

0.2mm(0.0079in.)

End gap

No. 1 ring

0.15 ~ 0.30mm(0.0059 ~ 0.0118in.)

0.6mm(0.0236in.)

No. 2 ring

0.30 ~ 0.45mm(0.0118 ~ 0.0177in.)

0.7mm(0.0275in.)

Oil ring

0.20 ~ 0.70mm(0.0078 ~ 0.0275in.)

0.8mm(0.0315in.)

Piston ring O.S.

0.25mm(0.0098in.)

Piston pin

Piston pin outer diameter

21.001 ~ 21.007mm(0.8268 ~ 0.8270in.)

Piston pin hole inner diameter

21.014 ~ 21.023mm(0.8273 ~ 0.8277in.)

Piston pin hole clearance

0.007 ~ 0.022mm(0.0003 ~ 0.0009in.)

Connecting rod small end inner diameter

20.974 ~ 20.985mm(0.8257 ~ 0.8262in.)

Connecting rod small end hole clearance

0.016 ~ 0.033mm(0.0006 ~ 0.0013in.)

Connecting rod

Connecting rod big end inner diameter

51.000 ~ 51.018mm(2.0079 ~ 2.0086in.)

Connecting rod bearing oil clearance

0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)

Side clearance

0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)

0.4mm(0.0157in.)

Crankshaft

Main journal outer diameter

61.982 ~ 62.000mm(2.4402 ~ 2.4409in.)

Pin journal outer diameter

47.982 ~ 48.000mm(1.8891 ~ 1.8898in.)

Main bearing oil clearance

0.004 ~ 0.022mm(0.0002 ~ 0.0009in.)

End play

0.07 ~ 0.25mm(0.0028 ~ 0.0098in.)

0.30mm(0.0118in.)

Oil pump

Relief valve opening pressure

490.33 ~ 588.40kPa(5.0 ~ 6.0kgf/cm

², 71.12 ~

85.34 psi)

Engine oil

Oil quantity (Total)

4.8 L (5.07 US qt, 4.22 lmp qt)

Oil quantity (Oil pan)

4.2 L (4.43 US qt, 3.69 lmp qt)

Oil quantity (Drain and refill including oil
filter)

4.5 L (4.75 US qt, 3.95 lmp qt)

Oil quality

ABOVE API SJ / SL or SAE 5W-20

Oil pressure

130kPa(1.32kgf/cm

²,18.77psi) [at

1000rpm,110°C(230°F)]

Cooling system

Cooling method

Forced circulation with electrical fan

Coolant quantity

8.2~8.3L(8.66~8.77U.S.qts,7.22~7.30lmp.qts)

Thermostat

Type

Wax pellet type

Opening temperature

82±2°C (179.6±35.6°F)

Fully opened
temperature

95°C (203°F)

Full lift

10mm (0.3937in.) or more

Radiator cap

Main valve opening
pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25 kg/cm

², 13.51 ~

17.78psi)

Vacuum valve opening
pressure

0.98 ~ 4.90 kpa(0.01 ~ 0.05 kg/cm

², 0.14 ~ 0.71

psi)

Engine coolant temperature sensor

Type

Thermister type

Resistance

20°C (68°F)

2.31 ~ 2.59 k

Ω

80°C(176°F)

0.3222 k

Ω

TIGHTENING TORQUE

Item

Quantity

Nm

kgf.m

lb-ft

Oil seal case bolt

3

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Main bearing cap bolt(M10)

8

29.4 + 90°

3.0 + 90°

21.7 + 90°

Main bearing cap bolt(M8)

8

15.7 + 90°

1.6 + 90°

11.6 ~ + 90°

Rear plate bolt

1

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil pump case bolt(8

×25)

1

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Oil pump case bolt(8

×35)

1

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

TimingOil pump case bolt(8

×65)

1

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

TimiOil relief plug

1

39.2 ~ 49.0

4.0 ~ 5.0

28.9 ~ 36.2

Oil filter bracket bolt(8

×35)

4

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Oil filter bracket bolt(8

×65)

2

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Oil filter insert

1

44.1 ~ 53.9

4.5 ~ 5.5

32.5 ~ 39.8

Timing chain cover bolt

21

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Upper oil pan bolt(8

×22)

15

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Upper oil pan bolt(163.5mm)

1

4.9 ~ 6.9

0.5 ~ 0.7

3.6 ~ 5.1

Upper oil pan bolt(154.5mm)

1

4.9 ~ 6.9

0.5 ~ 0.7

3.6 ~ 5.1

Lower oil pan bolt

11

9.8 ~ 11.8

1.0 ~ 1.2

7.2 ~ 8.7

Oil drain plug

1

34.3 ~ 44.1

3.5 ~ 4.5

25.3 ~ 32.5

Engine support bracket bolt(10

×94)

2

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Engine support bracket bolt(10

×102.5)

1

58.8 ~ 68.6

6.0 ~ 7.0

43.4 ~ 50.6

Camshaft bearing cap bolt(6

×38)

24

10.8 ~ 12.7

1.1 ~ 1.3

8.0 ~ 9.4

Camshaft bearing cap bolt(8

×38)

12

20.6 ~ 25.5

2.1 ~ 2.6

15.2 ~ 18.8

Cylinder head bolt

16

22.6~26.5 + (60°

+2°) + (45°+2°)

2.3~2.7 + (60°

±2°) + (45°±2°)

16.6~19.5 + (60°

+2°) + (45°+2°)

Cylinder head cover bolt

22

7.8 ~ 9.8

0.8 ~ 1.0

5.8 ~ 7.2

Crankshaft pulley bolt

1

166.7 ~ 176.5

17.0 ~ 18.0

123.0 ~ 130.2

Drive plate bolt

8

71.6 ~ 75.5

7.3 ~ 7.7

52.8 ~ 55.7

Connecting rod bearing cap bolt

12

19.6 ~ 90°

2.0 ~ 90°

14.5 ~ 90°

OCV(Oil Control Valve) bolt

2

7.8 ~ 9.8

0.8 ~ 1.0

5.8 ~ 7.2

CVVT & exhaust cam sprocket bolt

4

66.7 ~ 78.5

6.8 ~ 8.0

49.2 ~ 57.9

Timing chain auto tensioner bolt

4

10.8 ~ 12.7

1.1 ~ 1.3

8.0 ~ 9.4

Camshaft sprocket bolt

2

88.3 ~ 107.9

9.0 ~ 11.0

65.1 ~ 79.6

Timing belt idler bolt

1

49.0 ~ 58.8

5.0 ~ 6.0

36.2 ~ 43.4

Timing belt tensioner bolt

2

19.6 ~ 26.5

2.0 ~ 2.7

14.5 ~ 19.5

Timing belt tensioner arm bolt

1

34.3 ~ 53.9

3.5 ~ 5.5

25.3 ~ 39.8

Water pump bolt(8

×20)

3

14.7 ~ 21.6

1.5 ~ 2.2

10.8 ~ 15.9

Water pump bolt(8

×25)

4

14.7 ~ 21.6

1.5 ~ 2.2

10.8 ~ 15.9

Drive belt idler bolt

1

34.3 ~ 53.9

3.5 ~ 5.5

25.3 ~ 39.8

Drive belt tensioner bolt

1

34.3 ~ 53.9

3.5 ~ 5.5

25.3 ~ 39.8

Water pipe bolt

1

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.5

Water temp. control assembly nut

4

29.4 ~ 41.2

3.0 ~ 4.2

21.7 ~ 30.4

Oil level gauge bolt

1

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Oil screen bolt

2

14.7 ~ 21.6

1.5 ~ 2.2

10.8 ~ 15.9

Water outlet pipe bolt

3

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.5

Water inlet pipe bolt

2

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.5

Water inlet pipe nut

1

16.7 ~ 19.6

1.7 ~ 2.0

12.3 ~ 14.5

Surge tank bolt(8

×28)

3

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Surge tank bolt(8

×80)

2

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Surge tank nut

2

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Intake manifold bolt

4

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Intake manifold nut

4

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Surge tank bracket bolt

2

18.6 ~ 23.5

1.9 ~ 2.4

13.7 ~ 17.4

Exhaust manifold bolt

14

29.4 ~ 34.3

3.0 ~ 3.5

21.7 ~ 25.3

Heat protect bolt

6

16.7 ~ 21.6

1.7 ~ 2.2

12.3 ~ 15.9

Front muffler bolt

2

39.2 ~ 58.8

4.0 ~ 6.0

28.9 ~ 43.4