Kia Carnival (2009+). Manual — part 112

Arrange the main bearings and thrust bearings in the correct order.

13. Check fit between piston and piston pin.

Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a
set.

14. Remove piston rings.

(1) Using a piston ring expender, remove the 2 compression rings.

(2) Remove 2 side rails and the spacer by hand.

Arrange the piston rings in the correct order only.

15. Disconnect connecting rod from piston.

Using a press, remove the piston pin from piston.
(Press-in load : 800 ~ 1400kg (1764 ~ 3086lb)

INSPECTION

CONNECTING ROD AND CRANKSHAFT

1. Check the connecting rod end play.

Using a feeler gauge, measure the end play while moving the connecting rod back and forth.

Standard end play : 0.1~ 0.25mm(0.004 ~ 0.010in.)

A. If out-of-tolerance, install a new connecting rod.

B. If still out-of-tolerance, replace the crankshaft.

2. Check the connecting rod bearing oil clearance.

(1) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

(2) Remove 2 connecting rod cap bolts.

(3) Remove the connecting rod cap and bearing half.

(4) Clean the crank pin and bearing.

(5) Place plastigage across the crank pin.

(6) Reinstall the bearing half and cap, and torque the bolts.

Tightening torque
17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

Do not turn the crankshaft.

(7) Remove 2 bolts, connecting rod cap and bearinghalf.

(8) Measure the plastigage at its widest point.

Standard oil clearance
0.038 ~ 0.056mm(0.0015 ~ 0.0022in.)

(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new,

complete bearing with the same color mark (select the color as shown in the next column), and recheck the
clearance.

Do not file, shim, or 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 (the color listed

above or below that one), and check clearance again.

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

CLASS

MARK

INSIDE DIAMETER

0

a

58.000 ~ 58.006mm

(2.2834 ~ 2.2837in.)

1

b

58.006 ~ 58.012mm

(2.2837 ~ 2.2839in.)

2

c

58.012 ~ 58.018mm

(2.2839 ~ 2.2842in.)

CRANKSHAFT PIN MARK LOCATION

DISCRIMINATION OF CRANKSHAFT

DISCRIMINATION OF CRANKSHAFT

CLASS

MARK

OUTSIDE DIAMETER OF PIN

I

1 or A

54.966 ~ 54.972mm

(2.1640 ~ 2.1642in.)

II

2 or B

54.960 ~ 54.966mm

(2.1638 ~ 2.1640in.)

III

3 or C

54.954 ~ 54.960mm

(2.1635 ~ 2.1638in.)

PLACE OF IDENTIFICATION MARK (CONNECTING ROD BEARING)

DISCRIMINATION OF CONNECTING ROD BEARING

CLASS

MARK

THICKNESS OF BEARING

E

BLUE

1.514 ~ 1.517mm

(0.0596 ~ 0.0597in.)

D

BLACK

1.511 ~ 1.514mm

(0.0595 ~ 0.0596in.)

C

BROWN

1.508 ~ 1.511mm

(0.0594 ~ 0.0595in.)

B

GREEN

1.505 ~ 1.508mm

(0.0593 ~ 0.0594in.)

A

YELLOW

1.502 ~ 1.505mm

(0.0591 ~ 0.0593in)

(11) Selection

CONNECTING ROD IDENTIFICATION MARK

0(a)

1(b)

2(c)

CRANKSHAFT

INDENTIFICATION

MARK

1 or A

A

(YELLOW)

B

(GREEN)

C

(BROWN)

2 or B

B

(GREEN)

C

(BROWN)

D

(BLACK)

3 or C

C

(BROWN)

D

(BLACK)

E

(BLUE)

3. Check the crankshaft bearing oil clearance.

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

(2) Clean each main journal and bearing half with a clean shop tower.

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

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

Tightening torque
49.00Nm(5.0 kgf.m, 36.16lb-ft) + 90°
19.60 Nm(2.0 kgf.m, 14.46lb-ft)+ 120°
29.40 ~ 31.36Nm(3.0 ~ 3.2 kgf.m, 21.70 ~ 23.14lb-ft)

Do not turn the crankshaft.