Kia Carnival (2009+). Manual — part 188

3. Install the timing belt auto tensioner.

(1) Fixing the tensioner with a vice and compressing the rod, insert a set-pin.

- Handle the auto tensioner in the vertical position.
- If it is treated by laying, tilting or turning over, stand it vertically for about five minutes in order for air to

move upward.

- Do not pull the pin out before its installation to the engine assembly because pulling the pin can cause

noise of timing system by making aiir go in the high pressure chamber.

- When pressing the rod, use a vertical vice certainly.
- There is a high possibility for air to get in the high pressure chamber, when using a horizotal vice.
- Do not apply more load than 400N on the rod.
- Do not press the rod until its position is below 2.5mm from the body surface.
- The projection of the rod is secured more than 2.5mm.

- Repairing orders when disassembling the auto tensioner and reassembling it to the engine, or pulling

the pin out before its installation ;
1. Stand it vertically for about five minutes.
2. Press the rod with the force, 150~200N.
3. If the rod has a stiffness, press it slowly and insert the pin into the set hole.
4. If not(the tensioner is in 'sponge' state), press the rod slowly from its maximum projection to 2.9mm

position(the meeting point with the rod and the hole of the body) two or three times.
Afterwards, if stiffness is sensed, insert the pin into the hole. However, if not, scrap the tensioner.

(2) Install the auto tensioner(A) to the front case with the set-pin inserted.

Tightening torque
19.6 ~ 26.5Nm(2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

4. Ensure the timing marks on the camshaft and the crankshaft sprockets.

5. Install the timing belt.

Crankshaft sprocket(A) ! Idler(B) ! Bank 2 exhaust camsprocket(C) ! Water pump pulley(D) ! Bank 1 exhaust
camsprocket(E) ! Tensioner pulley(F).

6. Remove the auto tensioner set-pin.

7. Check the tension of the timing belt.

(1) Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at TDC.

After 5minutes, measure the length of the projected rod.

Specification
5 ~ 7mm(0.1969 ~ 0.2756in.)

(2) Ensure the locations of the timing marks for each sprocket.

8. Install the engine support bracket(A).

Tightening torque
58.8 ~ 68.6Nm(6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)

9. Install the timing belt lower cover(A).

Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.8 ~ 8.7lb-ft)

10. Install the crankshaft damper pulley(A).

Tightening torque
166.7 ~ 176.5Nm(17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft)

11. Install the engine mounting bracket(A).

Tightening torque
63.7 ~ 83.4Nm(6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

12. Install the timing belt upper cover(A).

Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

13. Install the drive belt tensioner(C).

Tightening torque
34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)

14. Install the drive belt idler and the drive belt(A).

Tightening torque
34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft)