Kia Carnival (2009+). Instruction - page 1

2.9L Diesel Supplement
Engine Mechanical System

General Information

Engine Mechanical System

2009 > D 2.9 VGT >

SPECIFICATIONS

Description

Specifications(J3 - ENG)

Limit

General

Type

In-line, DOHC

Number of cylinders

4

Bore

101.5~101.526mm (3.9961~3.9971in)

Stroke

98mm (8.8583in)

Total displacement

2,902 cc (177.08 cu.in)

Compression ratio

18.4 : 1

Firing order

1-3-4-2

Valve timing

Intake valve

Opens (ATDC)

26°

Closes (ABDC)

50°

Exhaust valve

Opens (BBDC)

72°

Closes (ATDC)

32°

Cylinder head

Flatness of gasket surface

Less than 0.05mm (0.0020in)

Flatness of manifold
mounting surface

Intake

Less than 0.15mm (0.0059in)

Exhaust

Less than 0.15mm (0.0059in)

Camshaft

Cam height

Intake

39.397 ~ 39.597mm (1.5511 ~ 1.5589in)

Exhaust

39.4932 ~ 39.6932mm (1.5548 ~ 1.5627in)

Journal outer Diameter (Intake, Exhaust)

27.941 ~ 27.960mm (1.1000 ~ 1.1008in)

Bearing oil clearance

0.040 ~ 0.080mm (0.0016 ~ 0.0031in)

End play

0.08 ~ 0.17mm (0.0031 ~ 0.0067in)

Valve

Valve length

Intake

126.24mm (4.9701in)

Exhaust

126.24mm (4.9701in)

Stem outer diameter

Intake

6.965 ~ 6.980mm (0.2742 ~ 0.2748in)

Exhaust

6.945 ~ 6.960mm (0.2734 ~ 0.2740in)

Face angle

45°

Thickness of valve
head (margin)

Intake

1.7mm (0.0669in)

Exhaust

1.6mm (0.0630in)

Valve stem to valve
guide clearance

Intake

0.030 ~ 0.065mm (0.0012 ~ 0.0026in)

Exhaust

0.050 ~ 0.085mm ( 0.0020~ 0.0033in)

Valve guide

Length

Intake

52.5mm (2.0669in)

Exhaust

52.5mm (2.0669in)

Valve seat

Width of seat contact

Intake

1.4 ~ 2.0mm (0.0551 ~ 0.0787in)

Exhaust

0.9 ~ 1.5mm (0.0354 ~0.0591 in)

Seat angle

45°

Valve spring

Free length

52.477mm (2.0660in)

Load(Intake)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.15±3.13kg/31.65mm(86.3±6.9 lb/1.2461 in)

Load(Exhaust)

Installed

23.45±1.87kg/40.0mm(51.7±4.1lb/1.5748 in)

Valve opened

39.43±3.15kg/31.50mm(86.9±6.9 lb/1.2402 in)

Out of squareness

Less than 2°

Rocker arm and rocker arm shaft

Rocker arm inner diameter

20.000 ~ 20.027mm (0.7874 ~ 0.7885in)

Rocker arm shaft outer diameter

19.959 ~ 19.980mm (0.7858 ~ 0.7866in)

Cylinder block

Cylinder bore

101.500 ~ 101.526mm (3.9961 ~3.9971 in)

Liner inner diameter

97.100 ~ 97.126mm (3.8228~ 3.8239in)

Liner outer diameter

101.480 ~ 101.526mm ( 3.9953~ 3.9971in)

Flatness of gasket surface

Less than 0.05mm (0.0020in)

Piston

Piston outer diameter

97.015 ~ 97.030mm ( 3.8195~ 3.8201in)

Piston to cylinder clearance

0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

Ring groove width

No. 1 ring groove

2.397 ~ 2.417mm ( 0.0944~0.0952 in)

No. 2 ring groove

2.05 ~ 2.07mm ( 0.0807~ 0.0815in)

Oil ring groove

3.02 ~ 3.04mm (0.1189 ~ 0.1197in)

Piston ring

Side clearance

No. 2 ring

0.06 ~ 0.10mm (0.0024~0.0039 in)

Oil ring

0.03 ~ 0.07mm (0.0012~0.0028 in)

End gap

No. 1 ring

0.25 ~ 0.40mm (0.0098~ 0.0157in)

No. 2 ring

0.40 ~ 0.55mm (0.0157~0.0217in)

Oil ring

0.20 ~ 0.40mm (0.0079 ~ 0.0157in)

Piston pin

Piston pin outer diameter

31.994 ~ 32.000mm (1.2596 ~ 1.2598 in)

Piston pin hole inner diameter

32.015 ~ 32.025mm (1.2604 ~ 1.2608 in)

Piston pin hole clearance

0.015 ~ 0.031mm (0.0006 ~ 0.0012 in)

Connecting rod small end inner diameter

32.012 ~ 32.033mm (1.2603 ~ 1.2611 in)

Connecting rod small end hole clearance

0.012 ~ -0.039mm (0.0005 ~ 0.0015 in)

Connecting rod

Connecting rod big end inner diameter

60.833 ~ 60.846mm (2.3950 ~ 2.3955 in)

Connecting rod bearing oil clearance

0.043 ~ 0.077mm (0.0017 ~ 0.0030 in)

End play

0.239~0.39 (0.0094 ~ 0.0154 in)

Crankshaft

Main journal outer
diameter

NO 1, 2, 4, 5

69.995 ~ 70.015mm (2.7557 ~2.7565 in)

NO 3

69.973~69.993mm (2.7548 ~2.7556 in)

Pin journal outer diameter

57.106~57.124mm (2.2483~2.2490 in)

Main bearing oil
clearance

NO 1, 2, 4, 5

0.045 ~ 0.079mm (0.0018 ~0.0031 in)

NO 3

0.067~0.101 mm (0.0026 ~0.0040 in)

End play

0.14 ~ 0.39mm (0.0055 ~0.0154 in)

Flywheel

Runout

0.10mm (0.0039in)

0.13mm (0.0051in)

Oil pump

Relief valve opening pressure

588.40±49.0kpa(6.0±0.5kg/cm!,85.34±7.1psi)

Discharge volume

75L/min(79.25 US qt/min, 65.99 lmp qt/min)
(engine3,800rpm)

Engine oil

Oil quantity (Total)

8.0 L (8.45 US qt, 7.03 lmp qt)

Oil quantity (Oil pan)

6.0 L (6.34 US qt, 5.27 lmp qt)

Oil quantity (Drain and refill including oil filter) 6.6 L (6.97 US qt, 5.08 lmp qt)

Oil quality

ABOVE API CH-4 or ABOVE ACEA B4

Oil pressure (Idle)

78.45 kpa (0.8 kg/cm!, 11.38 psi)

Cooling system

Cooling method

Forced circulation with cooling fan

Thermostat

Type

Wax pellet type

Opening temperature

88±1.5 °C (190.4 ±34.7 °F)

Pull opening
temperature

100 °C (212.0 °F)

Radiator cap

Main valve opening
pressure

93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm!, 13.51
~ 17.78psi)

Water temperature sensor

Type

Thermister type

Resistance

20°C (68°F)

2.27~2.64 k"

80°C (176°F)

0.31~0.33 k"

TIGHTENING TORQUE

Item

Quan-

tity

Tightening torque

N.m

kgf.m

lb-ft

Cylinder block

Engine support bracket bolts

8

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine mounting

Engine mounting insulator and engine mounting
bracket fixing nuts

4

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

Engine support bracket and engine mounting
insulator fixing nuts

2

36.3 ~ 53.9

3.7 ~ 5.5

26.8 ~ 39.8

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