Kia Carnival (2009+). Manual — part 116

• Remove harmful foreign matters on the sealing face before applying sealant
• Be assembling oil drain cover, the liquid sealant TB1217H should be applied oil drain cover.
• The part must be assembled within 5 minutes after sealant was applied.
• Apply sealant to the inner threads of the bolt holes.

13. Install rear oil seal case.

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.67lb-ft)

• Make clean the sealing face before assembling two parts.
• Remove harmful foreign matters on the sealing face before applying sealant
• Be assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case.
• The part must be assembled within 5 minutes after sealant was applied.
• Apply sealant to the inner threads of the bolt holes.

14. Using SST(09231-3C200, 09231-H1100), install rear oil seal.

15. Install baffle plate.

Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown.

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

16. Install upper oil pan.

A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. Before assebling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.

The part must be assembled within 5 minutes after the sealant was applied.

Bead width : 2.5mm(0.1in.)

• Ensure the sealing face is clean before assembling two parts.
• Remove harmful foreign matters on the sealing face before applying sealant
• When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
• To prevent leakage of oil, apply sealant gasket ot the inner threads of the bolt holes.

C. Install upper oil pan.

Uniformly tighten the bolts in several passes.

Tightening torque
9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

17. Install knock sensor.

Tightening torque
15.68 ~ 23.52Nm (1.6 ~ 2.4kgf.m, 11.57 ~ 17.36lb-ft)

18. Install drive plate.

Tightening torque
71.54 ~ 75.46Nm (7.3 ~ 7.7kgf.m, 52.80 ~ 55.69lb-ft)

INSTALLATION

1. Install power steering pump.

2. Install generator.

3. Install air conditioner compressor

4. Install oil filter assembly.

5. Install oil pump.

6. Install cylinder head.

7. Install water temperature control assembly.

8. Install timing chain.

9. Install intake manifold.

10. Install exhaust manifold.

2009 > G 3.8 DOHC >

ENGINE COOLANT REFILLING AND BLEEDING

Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high
pressure escaping from the radiator.

When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or
the paint. If any coolant spills, rinse it off immediately.

1. Make sure the engine and radiator are cool to the touch.

2. Remove radiator cap.

3. Loosen the drain plug, and drain the coolant.

4. Tighten the radiator drain plug securely.

5. Remove, drain and reinstall the reservoir. Fill the tank halfway to the "F" mark with water, then up to the "F" mark

with antifreeze.

6. Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the

radiator to ensure proper air bleeding.

• Use only genuine antifreeze/coolant.
• For best corrosion protection, the coolant concentration must be maintained year-round at 50% minimum.

Coolant concentrations less than 50% may not provide sufficient protection against corrosion or freezing.

• Coolant concentrations greater then 60% will impair cooling efficiency and are not recommended.

• Do not mix different brands of antifreeze/coolants.
• Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.

7. Start the engine.

When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.

8. Repeat 7 until the cooling fan cycles 3 ~ 5times and bleed air sufficiently out of the cooling system.

9. Install the radiator cap and fill the reservoir tank to the "MAX" line with coolant.

10. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.

11. Stop the engine and wait until the cooling system is cool to the touch.

12. Repeat 6 to 11 until the coolant level doesn't fall any more, bleed air out of the cooling system.

Proper cooling system operation depends on the absence of trapped air within the system. It is essential that
the cooling system be properly filled and bled before returning the vehicle to service.

CAP TESTING

1. Remove the radiator cap, wet its seal with engine coolant, then install it no pressure tester.