Kia Carnival 2009 User Manual
Engine Mechanical System
General Information
Engine Mechanical System
2009 > G 3.8 DOHC >
SPECIFICATION
Description Specifications Limit
General
Type V-type, DOHC
Number of cylinders 6
Bore 96mm(3.7795in)
Stroke 87.0mm(3.4252in)
Total displacement 3.778cc(230.55cu.in.)
Compression ratio 10.4
Firing order 1-2-3-4-5-6
Valve timing
Intake Opens(ATDC) 10°
Closes(ABDC) 62°
Exhaust Opens(BBDC) 42°
Closes(ATDC) 6°
Cylinder head
Flatness of gasket surface Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Flatness of
manifold mounting
Intake
Less than 0.1mm(0.0039in.)
[Less than 0.03mm(0.001in)/110x110]
Exhaust
Less than 0.1mm(0.0039in.)
[Less than 0.03mm(0.001in)/110x110]
Camshaft
Cam height LH
Camshaft
Intake 46.8mm(1.8425in.)
Exhaust 45.8mm (1.8031in.)
RH
Camshaft
Intake 46.8mm(1.8425in.)
Exhaust 45.8mm (1.8031in.)
Journal outer
diameter
LH
,RHcamshaft
Intake No.1: 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)
No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.)
Exhaust No.1: 27.964 ~ 27.980mm (1.1009 ~ 1.1016in.)
No.2,3,4: 23.954 ~ 23.970mm (0.9430 ~ 0.9437in.)
Bearing oil
clearance
LH
,RHcamshaft
Intake No.1: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust No.1: 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
End play 0.02 ~ 0.18mm (0.0008 ~ 0.0071in.)
Valve
Valve length Intake 105.27mm(4.1445in.)
Exhaust 105.50mm (4.1535in.)
Stem outer
diameter
Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)
Face angle 45.25° ~ 45.75°
Thickness of
valvehead(margin)
Intake 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)
Exhaust 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)
Valve stem to
Intake
0.07mm
valve guide
clearance
0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)
(0.00275in.)
Exhaust
0.030 ~ 0.054mm (0.00118 ~ 0.00212in.)
0.09mm
(0.00354in.)
Valve guide
Inner diameter Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)
Length Intake 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Exhaust 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)
Valve seat
Width of seat
contact
Intake 1.15 ~ 1.45mm(0.05118 ~ 0.05709in.)
Exhaust 1.35 ~ 1.65mm(0.05315 ~ 0.06496in.)
Seat angle Intake 44.75° ~ 45.20°
Exhaust 44.75° ~ 45.20°
Valve spring
Free length 43.86mm (1.7267in.)
Load 19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.)
42.3±1.3kg/24.2mm (93.3±2.9 lb/0.9527in.)
Out of squareness Less than 1.5°
MLA
MLA outer
diameter
Intake 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
Exhaust 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)
Cylinder head
tappet bore inner
diameter
Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)
Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)
MLA to tappet
bore clearance
Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
Exhaust 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
Valve clearance
Intake
0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)
Exhaust
0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)
Cylinder block
Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)
Flatness of gasket surface
Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
Piston outer diameter 95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
Ring groove width No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) 2.05mm (0.0807in.)
Piston ring
Side clearance No. 1 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)
No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)
Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.) 0.2mm (0.008in.)
End gap No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) 0.6mm (0.0236in.)
No. 2 ring 0.32 ~ 0.47mm (0.0126 ~ 0.0185in.) 0.7mm (0.0275in.)
Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in.) 0.8mm (0.0315in.)
Piston pin
Piston pin outer diameter 23.001 ~ 23.006mm (0.9055 ~ 0.9057in.)
Piston pin hole inner diameter 23.016 ~ 23.021mm (0.9061 ~ 0.9063in.)
Piston pin hole clearance 0.01 ~ 0.02mm (0.0039 ~ 0.0078in.)
Connecting rod small end inner diameter 22.974 ~ 22.985mm (0.9045 ~ 0.9049in.)
Connecting rod small end hole clearance -0.032 ~ -0.016mm (-0.0012 ~ 0.0006in.)
Connecting rod
Connecting rod big end innerdiameter 58.000 ~ 58.018mm(2.2834 ~2.2842in.)
Connecting rod bearing oil clearance 0.038 ~ 0.056mm (0.0015 ~ 0.0022in.)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)
Crankshaft
Main journal outer diameter 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)
Pin journal outer diameter 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)
Main bearing oil clearance 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.)
End play 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)
Oil pump
Relief valve opening pressure
450 ~ 550kPa
(4.59 ~ 5.61kgf/cm!,65.28 ~ 79.79psi)
Engine oil
Oil quantity (Total) 6.0 L (6.34 US qt, 5.27 lmp qt)
Oil quantity (Oil pan) 5.5 L (5.81 US qt, 4.83 lmp qt)
Oil quantity (Drain and refill including oil
filter)
5.2 L (5.49 US qt, 4.57 lmp qt)
Oil quality ABOVE API SJ / SL or SAE 5W-20
Oil pressure
130kPa(1.32kgf/cm!,18.77psi)
[at 1000rpm,110°C(230°F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.6L(9.09U.S.qts,7.57lmp.qts)
Thermostat Type Wax pellet type
Opening temperature 82±2°C (179.6±35.6°F)
Fully
openedtemperature
95°C (203°F)
Full lift 10mm (0.3937in.)
Radiator cap Main valve opening
pressure
93.16 ~ 122.58kpa
(0.95 ~ 1.25kg/cm!, 13.51 ~ 17.78psi)
Vacuum valve opening
pressure
0.98 ~ 4.90 kpa
(0.01 ~ 0.05kg/cm!, 0.14 ~ 0.71 psi)
Water temperature sensor
Type Thermister type
Resistance 20°C (68°F) 2.31 ~ 2.59K"
80°C(176°F) 0.3222 K"
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.
A. $ Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
$ Record the out-of-specification valve clearance measurements. They will be used later to determine the
required replacement adjusting tappet.
Valve clearance
Specification
Engine coolant temperature : 20°C [68°F]
Limit
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°) and align the groove with timing mark "T" of the lower timing
chain cover.
Do not rotate engine counterclockwise
(3) Check only valves indicated as shown. [NO. 4 cylinder : TDC/compression]. Measure the valve clearance.
(Refer to procedure step1))
7. Adjust the intake and exhaust valve clearance.
(1) Set the No.1 cylinder to the TDC/compression.
(2) Remove the timing chain.
Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location
of the sproket because the identification mark on the chain for TDC(Top Dead Center) can be erased.
(3) Remove the camshaft bearing caps(A).
(4) Remove the camshaft assembly(A).
(5) Remove MLAs.
(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.
Valve clearance(Engine coolant temperature: 20°C[68°F])
T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]
(8) Select a new tappet with a thickness as close as possible to the calculated value.
Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm
(0.1417in.)
(9) Place a new tappet on the cylinder head.
Appling engine oil at the selected tappet on the periphery and top surface.
(10) Install the intake and exhaust camshaft.
(11) Install the bearing caps
(12) Install the timing chain.
(13) Turn the crankshaft two turns in the operating direction(clockwise) and realign crankshaft sprocket and
camshaft sprocket timing marks(A).
(14) Recheck the valve clearance.
Valve clearance (Engine coolant temperature: 20°C[68°F])
[Specification]
Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)
2009 > G 3.8 DOHC >
SPECIAL SERVICE TOOLS
Tool (Number and name) Illustration Use
Crankshaft front oil seal
installer
(09231-3C100)
Installation of the front oil seal
Flywheel stopper
(09231-3C300)
Removal and installation of the flywheel and
crankshaft pulley.
Torque angle adapter
(09221-4A000)
Installation of bolts & nuts needing an angular
method
Valve stem seal remover
(09222-29000)
Remover of the valve stem seal
Valve stem seal remover
(09222-3C100)
Installation of the valve stem seal
Valve spring compressor &
holder
(09222-3K000)
(09222-3C300)
Removal and installation of the intake or
exhaust valve
A : 09222-3K000
B : 09222-3C300 (holder)
Crankshaft rear oil seal
installer
(09231-3C200)
(09231-H1100)
Installation of the crankshaft rear oil seal
A : 09231-3C200
B : 09231-H1100
Oil pan remover
(09215-3C000)
Removal of oil pan
Oil filter wrench
(09263-3C100)
Removal and installation of the oil filter
housing cover
2009 > G 3.8 DOHC >
TROUBLESHOOTING
Symptom Suspect area Remedy
Engine misfire with
abnormal internal
lower engine noises.
Worn crankshaft bearings.
Loose or improperly installed engine drive
plate.
Replace the crankshaft and bearings as
required.
Repair or replace the drive plate as required.
Worn piston rings.
(Oil consumption may or may not cause the
engine to misfire.)
Inspect the cylinder for a loss of compression.
Repair or replace as required.
Worn crankshaft thrust bearings
Replace the crankshaft and bearings as
required.
Engine misfire with
abnormal valve train
noise.
Stuck valves.
(Carbon buildup on the valve stem)
Repair or replace as required.
Excessive worn or mis-aligned timing chain. Replace the timing chain and sprocket as
required.
Worn camshaft lobes. Replace the camshaft and valve lifters.
Engine misfire with
coolant consumption.
• Malfunctioning cylinder head gasket and/or
cranking or other damage to the cylinder
head and engine block cooling system.
• Coolant consumption may or may not
cause the engine to overheat.
• Inspect the cylinder head and engine
block for damage to the coolant passages
and/or a malfunctioning head gasket.
• Repair or replace as required.
Engine misfire with
excessive oil
consumption.
Worn valves, guides and/or valve stem oil
seals.
Repair or replace as required.
Worn piston rings.
(Oil consumption may or may not cause the
engine to misfire)
• Inspect the cylinder for a loss of
compression.
• Repair or replace as required.
Engine noise on startup, but only lasting a
few seconds.
Incorrect oil viscosity.
• Drain the oil.
• Install the correct viscosity oil.
Worn crankshaft thrust bearing.
• Inspect the thrust bearing and crankshaft.
• Repair or replace as required.
Upper engine
noise,regardless of
engine speed.
Low oil pressure. Repair or replace as required.
Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stretched or broken timing chain and/or
damaged sprocket teeth.
Replace the timing chain and sprockets.
Worn timing chain tensioner, if applicable. Replace the timing chain tensioner as
required.
Worn camshaft lobes.
• Inspect the camshaft lobes.
• Replace the timing camshaft and valve
lifters as required.
Worn valve guides or valve stems. Inspect the valves and valve guides,then
repair as required.
Stuck valves. (Carbon on the valve stem or
valve seat may cause the valve to stay open.
Inspect the valves and valve guides, then
repair as required.
Worn drive belt, idler, tensioner and bearing. Replace as required.
Lower engine
Low oil pressure. Repair or required.
noise,regardless of
engine speed.
Loose or damaged drive plate. Repair or replace the drive plate.
Damaged oil pan, contacting the oil pump
screen.
• Inspect the oil pan.
• Inspect the oil pump screen.
• Repair or replace as required.
Oil pump screen loose, damaged or
restricted.
• Inspect the oil pump screen.
• Repair or replace as required.
Excessive piston-to-cylinder bore clearance.
• Inspect the piston, piston pin and cylinder
bore.
• Repair as required.
Excessive piston pin-to-piston clearance.
• Inspect the piston, piston pin and the
connecting rod.
• Repair or replace as required.
Excessive connecting rod bearing clearance Inspect the following components and repair
as required.
• The connecting rod bearings.
• The connecting rods.
• The crankshaft pin journals.
Excessive crankshaft bearing clearance. Inspect the following components, and repair
as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Incorrect piston, piston pin and connecting rod
installation
• Verify the piston pins and connecting rods
are installed correctly.
• Repair as required.
Engine noise under
load.
Low oil pressure Repair or replace as required.
Excessive connecting rod bearing clearance . Inspect the following components andrepair
as required :
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Excessive crankshaft bearing clearance. Inspect the following components, andrepair
as required.
• The crankshaft bearings.
• The crankshaft main journals.
• The cylinder block.
Engine will not crankcrankshaft will not
rotate.
Hydraulically locked cylinder.
• Coolant/antifreeze in cylinder.
• Oil in cylinder.
• Fuel in cylinder.
1. Remove spark plugs and check for fluid.
2. Inspect for broken head gasket.
3. Inspect for cracked engine block or
cylinder head.
4. Inspect for a sticking fuel injector and/or
leaking fuel regulator.
Broken timing chain and/or timing chain
and/or timing chain gears.
1. Inspect timing chain and gears.
2. Repair as required.
Material in cylinder.
• Broken valve
• Piston material
• Foreign material
1. Inspect cylinder for damaged components
and/or foreign materials.
2. Repair or replace as required.
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.
Engine Mechanical System
Timing System
Engine Mechanical System
2009 > G 3.8 DOHC >
COMPONENT
Engine Mechanical System
Cylinder Head Assembly
Engine Mechanical System
2009 > G 3.8 DOHC >
COMPONENTS
2009 > G 3.8 DOHC >
REMOVAL
• Use fender covers to avoid damaging painted surfaces.
• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal operating
temperature before removing it.
• When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
• Mark all wiring and hoses to avoid misconnection.
• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
Engine removal is required for this procedure.
1. Remove exhaust manifold.
2. Remove intake manifold.
3. Remove timing chain.
4. Remove water temperature control assembly.
5. Remove camshaft bearing cap(A).
6. Remove camshaft assembly(A).
7. Remove cylinder head bolts, then remove cylinder head.
(1) Uniformly loosen and remove the 16 cylinder head bolts, in several passes, in the sequence shown. Remove
the 16 cylinder head bolts and plate washers.
Head warpage or cracking could result from removing bolts in an incorrect order.
(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a
bench.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
DISASSEMBLY
Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original
position.
1. Remove MLAs(A).
2. Remove valves.
(1) Using SST(09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.
(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using SST(09222-29000), remove the valve stem seal.
Do not reuse old valve stem seals.
3. Remove OCV(A).
INSPECTION
CYLINDER HEAD
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in.)[Less than 0.02mm(0.0008in.)/150x150]
Flatness of manifold gasket surface
Standard : Less than 0.03mm(0.001in)/110x110
2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
VALVE AND VALVE SPRING
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter of the valve guide.
Valve guide I.D.
Intake / Exhaust : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)
(2) Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)
[Limit]
Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.
Margin
[Standard]
Intake : 1.56 ~ 1.86mm(0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm(0.06811 ~ 0.07992in.)
(4) Check the valve length.
Length
Intake : 105.27mm (4.1445in)
Exhaust : 105.50mm (4.1535in)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 43.86mm (1.7267in.)
Out-of-square : 1.5°
MLA
1. Inspect MLA.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust : 34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust : 35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)
3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)
CAMSHAFT
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 46.8mm (1.8425in.)
Exhaust : 45.8mm (1.8031in.)
If the cam lobe height is less than standard, replace the camshaft.
2. Inspect camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps.
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3) Remove the camshafts.
CVVT ASSEMBLY
1. Inspect CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.
(3) Wind tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm!, 21psi) to the port of the
camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)
When the oil splashes, wipe it off with a shop rag.
(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in
the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by
hand. Also, If excessive air leaks from the port, the lock pin may not be fully released.
Loading...