Kia Carnival (2009+). Manual — part 15

INSTALLATION

• Thoroughly clean all parts to be assembled.
• Always use a new cylinder head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take care not to bend it.
• Rotating the crankshaft, set the No. 1 piston at TDC.

1. Install the cylinder head gasket(A) on the cylinder block.

Ensure the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.

3. Install the cylinder head bolts.

(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.

After measuring the length of the cylinder head bolts, replace them, if necessary.
Long bolts : 132mm(5.1968in)
Short bolts :93mm(3.6614in)

(2) Install and tighten the 18 cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque :
Long bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 120°
Short bolts: 39.2Nm (4.0kgf.m, 28.9lb-ft)+ 90° + 90°

Always use new cylinder head bolts.

4. Install the camshaft(A) on the cylinder head.

Apply sealant before assembling the front bearing caps
(LOCTITE NO. 518 or equivalent).

5. Install the bearing caps aligning the cap numbers with the direction of the arrow marks.

6. Install the rockerarm shaft assembly(A) after bearing cap.

Tightening torque :
Nuts, Bolts: 17.7~26.5Nm (1.8 ~ 2.7kgf.m, 13.0~19.5lb-ft)
Small nuts: 7.8~11.8Nm (0.8 ~ 1.2kgf.m, 5.8~8.7lb-ft)

Distinguish between the intake and the exhaust rocker arm shaft (Intake: yellow, exhaust: black).

7. Install the camshaft oil seal.

8. Install the timing belt plate(A).

Tightening torque :
7.8 ~ 11.8Nm (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

When assembling upper plate to the cylinder head assembly, be sure to use including solid sealant bolts at
marked 2ea point (B).
An upper plate mounting bolt can not be reused once it is removed and never use normal flange bolt with
applying anaerobic or liquid sealant to it. If not, the bolts may be loosened or damaged. In this case, replace
them with including solid sealant bolts.

9. Install the cylinder head cover.

(1) Apply sealant on the cylinder head as shown below.

(2) Before installing the cylinder head cover, check the clearance (A) between dowel pin on the edge of the

camshaft and the phase sensor.

Clearance (A) :

0.5 ~ 1.5mm (0.0197 ~ 0.0591in.)

(3) Install the cover (A) to the cylinder head after the gasket.

Tightening torque :
8.8~10.8Nm (0.9~1.1kgf.m, 6.5~8.0lb-ft)

10. Install the thermostat housing (B), the generator fixing bracket (A), and the water hose(C).

Tightening torque :
18.6~27.5Nm (1.9~2.8kgf.m, 13.7~20.3lb-ft)

11. Install the generator(A) with the fixing bolts(B,C), nut(D).

Tightening torque :
38.2~58.8Nm (3.9~6.0kgf.m, 28.2~43.4lb-ft)