Kia Carnival (2007 year). Manual — part 419

4. Apply oil on the piston pin when assembling.

LADDER FRAME AND BALANCE SHAFT

1. Measure the ladder frame inner diameter.

Ladder frame inner diameter

LH1

25.000 ~ 25.021 mm(0.9843~0.9851in)

LH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

LH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

RH1

35.000 ~ 35.025 mm(1.3780~1.3789in)

RH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

RH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

2. Measure the balance shaft outer diameter.

Balance shaft outer diameter

LH1

24.939 ~ 24.960 mm(0.9818~0.9827in)

LH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

LH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

RH1

34.925 ~ 34.950 mm(1.3750~1.3760in)

RH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

RH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

3. Measure the end play of the balance shaft.

0.10~0.25mm (0.0036~0.0098in)

OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil

pressure switch.

2. Check the continuity between the terminal and the body when the oil hole is blocked with a fine stick. If there is

continuity with a fine stick is pushed, replace the switch.

3. If there is no continuity when a 49.0kpa (0.5kg/cm², 7.1psi) pressure is applied through the oil hole, the switch is

operating properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

REASSEMBLY

a. Thoroughly clean all parts to assembled.
b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
c. Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble the piston and connecting rod.

(1) Insert the piston pin and fix the piston pin clip.

(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.

2. Install the piston rings.

(1) Install the oil ring expander and two side rails by hand.

(2) Using a piston ring expander, install the two compression rings with the code mark facing upward.

(3) Position the piston rings so that the ring ends are as shown.

3. Install the connecting rod bearings.

(1) Align the bearing (A) claw with the groove of the connecting rod and bearing cap (B).

(2) Install the bearings (A) in the connecting rod and bearing cap (B).

4. Install the crankshaft main bearings.

Upper bearings have oil grooves of the oil holes; Lower bearings do not.

(1) Aligning the bearing protrusions with the grooves of the cylinder block, push in the 5 upper bearings (A).

(2) Aligning the bearing protrusions with the grooves of the main bearing cap, and push in the 5 lower bearings.

5. Install the thrust bearings.

Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing
outward.

6. Place the crankshaft on the cylinder block.

7. Place the main bearing caps on the cylinder block.

8. Install the main bearing cap bolts.

a. The main bearing cap bolts are tightened in 2 progressive steps.
b. If any of the bearing cap bolts is broken or deformed, replace it.

(1) Apply a light coat of engine oil on the threads of the main bearing cap bolts.

(2) Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown.

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

(3) Check that the crankshaft turns smoothly.

9. Check the crankshaft end play.

10. Install the piston and connecting rod assemblies.

a. Before installing the piston, apply a coat of engine oil to the piston ring grooves and the cylinder bores.
b. When installing the piston pin to the piston, apply engine oil sufficiently

(1) Remove the connecting rod bearing caps and insert short sections of rubber hose over the threaded ends of

the connecting rod bolts.

(2) Install the ring compressor, checking that the rings are securely in place and positioning the piston in the

cylinder, tap it in using the wooden handle of a hammer.

(3) Stop inserting after the ring inserted in the cylinder, and check the connecting rod to crank journal alignment

before complete inserting.

(4) Apply engine oil to the bolt threads after removing rubber hose. Install the connecting rod caps with bearings,

and tighten the nuts.