Kia Carnival (2009+). Manual — part 184

Seized crankshaft or connecting rod bearings.

1. Inspect crankshaft and connecting rod

bearing.

2. Repair as required.

Bent or broken connecting rod.

1. Inspect connecting rods.
2. Repair as required.

Broken crankshaft.

1. Inspect crankshaft.
2. Repair as required.

2009 > G 2.7 DOHC >

Compression pressure inspection

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

1. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F).

2. Remove the surge tank.

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

4. 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) Open the throttle fully.

(3) With the fully-open throttle in cranking, measure the compression pressure.

Always use a fully charged battery to get the 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: 1,176.79kPa (12.0kgf/cm!, 170.68psi) - 200 ~ 250rpm
Minimum pressure: 1,029.69kPa (10.5kgf/cm!, 149.34psi)
Difference between cylinders: 98.07kPa (1.0kgf/cm!, 14.22psi)

(4) If the compression pressure in 1 or more cylinders is lower than the specification above, pour a small amount

of engine oil into the cylinder through the spark plug hole, repeat the steps (1) through (3) for the cylinder and
measure the pressure again.

A. If adding oil increases the pressure up, the piston rings or cylinder bores might be worn or damaged.
B. If the pressure doesn't increase, a valve may be sticking or seating may be improper, or there may be

leakage from the gasket.

6. Reinstall the spark plugs.

7. Install the ignition coils and connect 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
±5°C(59~77°F)) 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) Remove the cylinder head cover.

5. Set the piston of the No.1 cylinder to TDC(Top Dead Center) position.

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

(2) Check that the timing marks of the camshaft sprocket are in straight line on that of the cylinder head cover

surface as shwn in the illustration. It makes the piston of the No.1 cylinder position at TDC.

If not, turn the crankshaft one revolution clockwise.

6. Inspect the intake and the exhaust valve clearance.

(1) With the piston of the No.1 cylinder positioning at TDC, the valves which can be measured its clearance are as

shown below.

Measurement method.

A. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
B. Record the out-of-specification valve clearance measurements. They will be used later to determine the

required adjusting tappet for replacement.

Specification
Limit (Engine coolant temperature : 20°C [68°F])
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.)

(2) Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing mark "T" of the

timing chain cover.

(3) With the piston of the No.4 cylinder positioning at TDC, the valves which can be measured its clearance are as

shown below.

7. Adjust the intake and the exhaust valve clearances.

(1) Set the piston of the No.1 cylinder to the TDC/position.

(2) Remove the timing belt.

(3) Remove the camshaft bearing caps(A, B).

(4) Remove the camshaft assembly.

(5) Remove MLA(Mechanical Lash Adjuster)s.

(6) Measure the thickness of the removed tappet using a micrometer.

(7) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

T : Thickness of removed tappet
A : Measured valve clearance