Kia Carens. Manual - part 38

19. Install air intake hose and freash air duct.

20. Install accelerator cable and cruise control cable if equipped.

21. Check accelerator cable deflection. If deflection is not correct adjust by turning nut/ (A).

Deflection : 0.04~0.12in (1~3mm)

22. Connect PCV hose and ventilation hose.

23. Install ignition coils and high-tension cords.

24. Install center cover.

Tightening torque : 2.9~5.1lb·ft (3.9~6.9N·m, 0.4~0.7kg-m)

25. Connect negative battery cable.

(Refer to Timing belt installation)

26. Fill engine coolant with specified type and amount. (Refer to cooling system)

27. Start engine and check for oil and coolant leaks.

INSPECTION

Cylinder head and cylinder head gasket

1. Check cylinder head gasket for obvious signs of leakage, coolant stains on gasket, or combustion burns

across cylinder.

2. Clean cylinder head and cylinder block mounting surfaces of all gasket material.

Do not allow gasket material to fall oil pressages or oil control plug.

3. Measure cylinder head for straightness in six directions as shown in firgure.

Distortion : 0.004in (0.10mm) Maximum

4. If distortion exceed specification, resurface or replace cylinder head. Only remove the amount of material

required to achieve a flat surface.

Maximum material removal : 0.004in. (0.1mm)

5. Check cylinder head height.

Height : 5.272~5.276in (133.9~134.1mm)

6. If cylinder head height is not within specification, replace cylinder head.

If cylinder head requires machining, remove intake and exhaust manifolds and check their mount
surfaces for straightness.

7. Measure intake and exhaust manifold mating surface distortion at two directions shown in figure.

Distortion : 0.008in (0.20mm) Maximum

8. If distortion exceeds specification resurface or replace cylinder head.

Maximum material removal : 0.008in (0.20mm)

9. Check cylinder block for distortion of cylinder head mating surface (block deck) in six directions shown in

figure.

Disctorion : 0.006in (0.15mm) Maximum

10. If distortion exceeds specification, resurface block deck.

Maximum material removal : 0.0008in (0.20mm)

Cylinder head

1. Inspect cylinder head for damage, cracks and leakage of oil and water. Replace cylinder head if necessary.

2. Measure cylinder head mating surface in six directions as shown in figure.

Distortion : 0.004in (0.10mm) maximum

Before resurfacing cylinder head, check following repair or replace cylinder head if necessary.

• Sunken valve seats.
• Damage at intake and exhaust manifold mating surfaces.
• Camshaft oil clearances and end play.

3. Grind cylinder head mating surface if distortion exceeds specification.

Distortion : 0.004in (0.10mm) maximum

4. Check cylinder head height by measuring from cylinder deck surface to cylinder head cover gasket surface.

5. If cylinder head height is not within specification, replace cylinder head.

Height : 5.272~5.28in (133.9~134.1mm)

6. Measure intake and exhaust manifold mating surface distortion at two direction at two directions shown in

figure.

Distortion : 0.008in (0.20mm) maximum

7. If distortion exceeds specification, resurface or replace cylinder head.

Distortion : 0.008in (0.20mm) maximum