Kia Carnival (2009+). Manual — part 100

TIGHTENING TORQUE

Item

Quantity

Nm

kgf.m

lb-ft

Crankshaft pulley bolt

1

284.2 ~ 303.8

29.0 ~ 31.0

209.76 ~ 224.22

Timing chain cover bolt B

17

18.62 ~ 21.56

1.9 ~ 2.2

13.74 ~ 15.91

Timing chain cover bolt C

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt D

1

58.80 ~ 68.80

6.0 ~ 7.0

43.40 ~ 50.63

Timing chain cover bolt E

1

58.80 ~ 68.80

6.0 ~ 7.0

43.40 ~ 50.63

Timing chain cover bolt F

2

24.50 ~ 26.46

2.5 ~ 2.7

18.08 ~ 19.53

Timing chain cover bolt G

4

21.56 ~ 23.52

2.2 ~ 2.4

15.91 ~ 17.36

Timing chain cover bolt H

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt I

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain cover bolt J

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cam to cam guide bolt

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain auto tensioner bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain auto tensioner nut

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Timing chain guide bolt

4

19.60 ~ 24.50

2.0 ~ 2.5

14.17 ~ 18.08

Oil pump chain cover bolt

3

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain tensioner bolt

1

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain guide bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil pump chain sprocket bolt

1

18.62 ~ 21.56

1.9 ~ 2.2

13.74 ~ 15.91

Lower oil pan bolt

13

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Drive belt auto tensioner bolt(M12)

1

96.04 ~ 99.96

9.8 ~ 10.2

70.88 ~ 73.78

Drive belt auto tensioner bolt(M8)

1

17.64 ~ 21.56

1.8 ~ 2.2

13.02 ~ 15.91

Drive belt idler bolt

1

53.90 ~ 57.82

5.5 ~ 5.9

39.78 ~ 42.67

OCV(oil control valve) bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cylinder head bolt

16

(37.3~41.2) +

(118~122°) +

(88~92°)

(3.8~4.2) +

(118~122°) +

(88~92°)

(27.5~30.4) +

(118~122°) +

(88~92°)

Cylinder head bolt

1

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

CVVT & exhaust cam sprocket bolt

4

64.68 ~ 76.44

6.6 ~ 7.8

47.74 ~ 56.42

Camshaft bearing cap bolt

32

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Cylinder head cover bolt

38

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Connecting rod bearing bolt

12

(17.7~21.6) +

(88~92°)

(1.8~2.2) +

(88~92°)

(13.0~15.9) +

(88~92°)

Main bearing cap inner bolt(M11)

8

49.00 + 90°

5.0 + 90°

36.16 + 90°

Main bearing cap outer bolt(M8)

8

19.60 + 120°

2.0 + 120°

14.46 + 120°

Main bearing cap side bolt(M8)

6

29.40 ~ 31.36

3.0 ~ 3.2

21.70 ~ 23.14

Oil drain cover bolt

6

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Rear oil seal case bolt

6

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Baffle plate bolt

12

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Upper oil pan bolt

16

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Knock sensor bolt

2

15.68 ~ 23.52

1.6 ~ 2.4

11.57 ~ 17.36

Drive plate bolt cap

8

71.54 ~ 75.46

7.3 ~ 7.7

52.80 ~ 55.69

Oil filter cap

24.50

2.5

18.08

Oil drain bolt cap

1

34.30 ~ 44.10

3.5 ~ 4.5

25.31 ~ 32.55

Oil pump bolt

3

19.6 ~ 23.5

2.0 ~ 2.4

14.5 ~ 17.4

Oil filter body bolt

10

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Oil filter body cover bolt

11

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water vent hose bolt(Timing chain cover bolt L)

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water pump bolt(Timing chain cover bolt K)

1

21.56 ~ 26.46

2.2 ~ 2.7

15.91 ~ 19.53

Water pump bolt

4

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Water pump pulley bolt

4

7.84 ~ 9.80

0.8 ~ 1.0

5.78 ~ 7.23

Water temp. control nut

4

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Water temp. control bolt

2

18.62 ~ 23.52

1.9 ~2.4

13.74 ~ 17.36

Water inlet pipe bolt

3

16.66 ~ 19.60

1.7 ~ 2.0

12.30 ~ 14.47

Air vent pipe bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Intake manifold bolt

6

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Intake manifold nut

2

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Surge tank bolt (M8 # 25)

3

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Surge tank bolt (M6 # 106)

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Surge tank nut

1

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

Breather pipe bolt

2

9.80 ~ 11.76

1.0 ~ 1.2

7.23 ~ 8.68

Surge tank bracket bolt rear (M10 # 18 )

2

27.44 ~ 31.36

2.8 ~ 3.2

20.25 ~ 23.14

Surge tank bracket bolt front (M8 # 16)

2

18.62 ~ 23.52

1.9 ~ 2.4

13.74 ~ 17.36

ETC bracket bolt

2

15.68 ~ 25.48

1.6 ~ 2.6

11.57 ~ 18.80

Exhaust manifold nut

16

39.20 ~ 44.10

4.0 ~ 4.5

28.93 ~ 32.55

Heat proctor bolt

8

3.9 ~ 5.9

0.4 ~ 0.6

2.89 ~ 4.34

Front muffler

2

39.20 ~ 58.80

4.0 ~ 6.0

28.93 ~ 43.40

COMPRESSION

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression
pressure.

1. Warm up and stop engine.

Allow the engine to warm up to normal operating temperature.

2. Remove the surge tank.

3. Remove the ignition coil connectors(A) and ignition coils(B).

4. Remove the spark plugs.

Using a 16mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.

(1) Insert a compression gauge into the spark plug hole.

(2) Fully open the throttle.

(2) Fully open the throttle.

(3) After 7 times of cranking the engine, measure the compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.

Repeat steps 1) through 3) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure :
1,225kPa (12.5kgf/cm!, 177psi) - 200 ~ 250rpm
Minimum pressure :
1,078kPa (11.0kgf/cm!, 156psi)

(4) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder

through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.

A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or

damaged.

B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the

gasket.

6. Reinstall the spark plugs.

7. Install the ignition coil and ignition coil connectors.

8. Install the surge tank.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C) and cylinder
head is installed on the cylinder block.

1. Remove the engine cover.

2. Remove air cleaner assembly.

3. Remove the surge tank.

4. Remove the cylinder head cover.

(1) Disconnect the ignition coil connector and remove the ignition coil.

(2) Disconnect the breather pipe assembly(A) from the cylinder head cover.

(3) Loosen the cylinder head cover bolts and then remove the cover(A) and gasket.

5. Set No.1 cylinder to TDC/compression.

(1) Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.

(2) Check that the mark(A) of the camshaft timing sprockets are in straight line on the cylinder head surface as

shown in the illustration.
If not, turn the crankshaft one revolution (360°)

Do not rotate engine counterclockwise

6. Inspect the valve clearance.

(1) Check only the valve indicated as shown. [No. 1 cylinder : TDC/Compression] measure the valve clearance.

Measurement method.