Kia Carnival (2009+). Manual — part 113

(5) Remove the cap and bearing again, and measure the widest part of the plastigage.

Standard oil clearance
0.022 ~ 0.040mm (0.0009 ~ 0.0016in.)

(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,

complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or scrape the bearings or the caps to adjust clearance.

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed

above or below that one), and check clearance again.

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.

Crankshaft bore mark location
Letters have been stamped on the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct
bearings.

DISCRIMINATION OF CYLINDER BLOCK

CLASS

MARK

INSIDE DIAMETER

a

A

73.500 ~ 73.506mm
(2.8937 ~ 2.8939in.)

a

A

(2.8937 ~ 2.8939in.)

b

B

73.506 ~ 73.512mm
(2.8939 ~ 2.8942in.)

c

C

73.512 ~ 73.518mm
(2.8942 ~ 2.8944in.)

CRANKSHAFT JOURNAL MARK LOCATION

DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT

CLASS

MARK

OUTSIDE DIAMETER OF JOURNAL

I

1 or A

68.954 ~ 68.960mm
(2.7147 ~ 2.7150in.)

II

2 or B

68.948 ~ 68.954mm
(2.7145 ~ 2.7147in.)

III

3 or C

68.942 ~ 68.948mm
(2.7142 ~ 2.7145in.)

PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING)

DISCRIMINATION OF CRANKSHAFT BEARING

CLASS

MARK

THICKNESS OF BEARING

E

BLUE

2.277 ~ 2.280mm

(0.0896 ~ 0.0897in.)

D

BLACK

2.274 ~ 2.277mm

(0.0895 ~ 0.0896in.)

C

BROWN

2.271 ~ 2.274mm

(0.0894 ~ 0.0895in.)

B

GREEN

2.268 ~ 2.271mm

(0.0893 ~ 0.0894in.)

A

YELLOW

2.265 ~ 2.268mm

(0.0892 ~ 0.0893in.)

SELECTION

CRANKSHAFT BORE IDENTIFICATION MARK

a(A)

b(B)

c(C)

CRANKSHAFT

IDENTIFICATION MARK

1 or A

A

(YELLOW)

B

(GREEN)

C

(BROWN)

2 or B

B

(GREEN)

C

(BROWN)

D

(BLACK)

3 or C

C

(BROWN)

D

(BLACK)

E

(BLUE)

4. Check crankshaft end play.

Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

Standard end play
0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

If the end play is greater than maximum, replace the thrust bearings as a set.

Thrust bearing thickness
2.41 ~ 2.45mm(0.0949 ~ 0.0964in.)
Standard end play
0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

5. Inspect main journals and crank pins

Using a micrometer, measure the diameter of each main journal and crank pin.

Main journal diameter : 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Crank pin diameter : 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)

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 :
0.05mm / 100mm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
0.1mm / 100mm (0.0039 in./3.94 in.) or less

CYLINDER BLOCK

1. Remove gasket material.

Using a gasket scraper, remove all the gasketmaterial from the top surface of the cylinder block.

2. Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for
warpage.

Flatness of cylinder block gasket surface
Standard : Less than 0.05mm(0.0020 in.),Less than 0.02mm(0.0008in.) / 150 x 150