Kia Carnival (2009+). Manual — part 23

(8) Measure the plastigage at its widest point.

Standard oil clearance
0.043 ~ 0.077mm (0.0017 ~ 0.0030in)

(9) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new

bearings with the same color mark. (Refer to connecting rod bearing selection table)
Recheck the oil clearance.

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

(10) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. ( Refer to

connecting rod bearing selection table))
Recheck the oil clearance.

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.

Connecting rod mark location

Discrimination of connecting rod

Mark

Connecting rod big-endinner diameter

1

60.833 ~ 60.839mm

(2.3950 ~ 2.3952 in)

2

60.839 ~ 60.846mm

(2.3952 ~ 2.3955 in)

CRANKSHAFT PIN JOURNAL

Journal outer diameter
57.106~57.124mm (2.2483~2.2490in)

CONNECTING ROD BEARING MARK LOCATION

Discrimination of crankshaft pin journal

Color

Connecting rod bearing thickness

Blue

1.0828~1.832mm

(0.0720~0.0721in)

Red

1.832~1.836mm

(0.0721~0.0723in)

(11) Select the bearing by using the selection table.

Connecting rod bearing selection table

Connecting rod mark

Connecting rod bearing thickness

Oil clearance

1

Blue

0.045~0.077mm(0.0018~0.0030in)

2

Red

0.043~0.076mm(0.0017~0.0030in)

3. Check the 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 :
0.04mm / 50mm (0.0016in / 1.9685in ) or less
Allowable twist of connecting rod :
0.1mm / 50mm (0.0039in / 1.9685in) or less

4. Check the crankshaft bearing oil clearance.

(1) To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.

(2) Clean each main journal and lower bearing with a clean shop towel.

(3) Place one strip of plastigage across each main journal.

(4) Reinstall the lower bearings and caps, then tighten the bolts.

Tightening torque :
63.7~73.5Nm(6.5~7.5kgf.m, 47.0~54.2lb-ft)+105°~115°

Do not turn the crankshaft.

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

Standard oil clearance :
No.1, 2, 3, 5: 0.045~0.079mm (0.0018 ~0.0031 in)
No.3: 0.067~0.101 mm (0.0026 ~0.0040 in)

(6) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new

bearings with the same color mark. (Refer to crankshaft main bearing selection table).
Recheck the oil clearance.

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

(7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to crankshaft

main bearing selection table).
Recheck the oil clearance.

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.

CYLINDER BLOCK CRANKSHAFT JOURNAL BORE MARK LOCATION
Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct
bearings.

Discrimination of cylinder block crankshaft journal bore

Mark

Cylinder block crankshaft journal bore inner diameter

A

74.066~74.075mm

(2.9160~2.9163in)

None

74.075~74.084mm

(2.9163~2.9167in)

C

74.084~74.092mm

(2.9167~2.9170in)

Crankshaft main journal mark location

Discrimination of crankshaft main journal

Mark

Crankshaft main journalouter diameter

No.1, 2, 3, 5 journal

No.3 journal

1

69.995~70.002mm(2.7557~2.7560in)

69.973~69.980mm(2.7548~2.7551in)

*

70.002~70.009mm(2.7560~2.7563in)

69.980~69.987mm(2.7551~2.7554in)

3

70.009~70.015mm(2.7563~2.7565in)

69.987~69.993mm(2.7554~2.7556in)

Crankshaft main bearing mark location