Engine Mechanical System

Engine Mechanical System

Model : Carnival / Sedona

 Engine Mechanical System

Engine Mechanical System

General Information

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

SPECIAL SERVISE TOOLS

Tool (Number and name) Illustrator Used

OK130 990 007 Used to disassemble and assemble

Engine stand engine.

OK552 101 001 Used to disassemble and assemble

Hanger, engine stand engine.

OK201 170 AA0

Used to remove and replace engine
Engine support

OK590 111 001

Used to prevent engine rotation.
Brake ring gear

OK993 120 001

Used to remove and install valve.
Arm, valve spring lifter
OK993 120 004
Used to remove and install valve.
Pivot, valve spring lifter

OK993 110 AA0 Used to remove and install pistom

Piston pin set pin.

OK201 120 111

Used to remove and install guide.
Remover & installer, valve guide

OK993 120 006

Used to remove valve seal
Remover, valve seal

OK201 120005
Used to install valve seal
Installer, valve seal

OK130 283 021

Used to remove tie-rod end.
Puller, ball joint

OK670 140 015

Used to inspect pressure
Oil pressure gauge

SPECIAL SERVISE TOOLS

Tool (Number and name) Illustrator Used

OK130 990 007 Used to disassemble and assemble
Engine stand engine.

OK552 101 001 Used to disassemble and assemble

Hanger, engine stand engine.

OK201 170 AA0

Used to remove and replace engine
Engine support

OK590 111 001

Used to prevent engine rotation.
Brake ring gear

OK993 120 001

Used to remove and install valve.
Arm, valve spring lifter

OK993 120 004

Used to remove and install valve.
Pivot, valve spring lifter
OK993 110 AA0 Used to remove and install pistom
Piston pin set pin.

OK201 120 111

Used to remove and install guide.
Remover & installer, valve guide

OK993 120 006

Used to remove valve seal
Remover, valve seal

OK201 120005
Used to install valve seal
Installer, valve seal

OK130 283 021

Used to remove tie-rod end.
Puller, ball joint

OK670 140 015

Used to inspect pressure
Oil pressure gauge
 2000 > 2.5L GASOLIN(K5) >

TROUBLESHOOTING

Problem Possible cause Action

Engine will not crank Battery, starting system or other electrical Refer to starting system,
problems section EE, charging system,
section EE, or Wiring Diagram
Manual
Remove with suction gun, then
Liquid in combustion chamber crank engine cover with spark
plugs removed
Seized engine Repair
Engine cranks normally but Fuel system malfunction Refer to fuel system, section FL
does not start
Refer to ignition system section
Ignition system malfunction
EE
Improper valve clearance Check HLA's
Refer to exhaust system,
Restricted exhaust system
section EC
Inspect timing belt and related
Timing belt and/or related parts
part : replace if necessary
Low compression due to : stuck or burned Perform a compression test : as
valves : worn piston ring or cylinder ; failed outlined in this section : repair
cylinder head gasket engine as necessary.
Camshaft worn Replace
Poor idle quality Fuel system malfunction Refer to fuel system
Refer to emission control
Emission system malfunction
system, section EC
Refer to ignition system, section
Ignition system malfunction
EE
Improper valve clearance Check HLA's
Perform a compression test, as
Uneven cylinder compression outlined in this section : repair
engine as necessary
Poor valve-to-valve seat contact Repair or replace
Broken valve spring Repair
White exhaust smoke Usually caused by water vapor, which is a
normal by-product of combustion on cold None required
days
Excessive white smoke with engine
warmed up could be caused by a failed
cylinder head or intake gasket. Could also Repair or replace
be a cracked block, cylinder head or intake
manifold
Black exhaust smoke Fuel system malfunction Refer to fuel system section FL
 Refer to emission control
Emission system malfunction
system, section EC
Usually caused by oil burning in
combustion chambers from : worn rings,
Blue exhaust smoke Replace
worm valve guides, worn valve seals or
failed cylinder head gasket.
Valve train noise Worn valve guides Repair
Low oil pressure Refer to lubrication system
Improper valve clearance Check HLA's
Broken valve spring Replace
Sticking valve Free valves
Camshaft worn or faulty Replace
Insufficient power Insufficient compression caused by :
1. Improper valve clearance 1. Check HLA's
2. Leakage from valve seat 2. Repair or replace
3. Seized valve stem 3. Replace
4. Weak or broken valve spring 4. Replace
5. Failed cylinder head gasket 5. Replace
6. Cracked or distorted cylinder head 6. Repair or replace
7. Sticking, damaged or worn piston ring 7. Replace
8. Cracked or worn piston 8. Replace
Fuel system malfunction Refer to fuel system
Slipping clutch Refer to clutch
Dragging brakes Refer to wheels and tires
Restricted exhaust system Refer to exhaust system.
Abnormal combustion Improper valve clearance Check HLA's
Sticking or burned valve spring Replace
Weak or broken valve spring Replace
Carbon accumulation in combustion
Refer to exhaust system
chamber
Engine knocks at idle when hot Loosen or worn accessory drive Check belts and tensioners
belt/tensioner Replace if necessary
A/C compressor or generator bearing Replace
Install proper oil viscosity for
Improper oil viscosity
expected temperatures
Install proper oil viscosity for
Excessive piston pin clearance
expected temperatures
Check and replace rods if
Connecting rod clearance
necessary.
Hone and replace rods if
Insufficient piston-to-bore clearance
necessary.
Faulty timing belt tensioner or guide Replace
Loose damper pulley Tighten or replace if necessary.
Slight noise at idle, becomes Valve spring clicking on cap, off square or
Repair or replace
louder as engine speed is broken
increased
Excessive stem to guide clearance Repair
Excessive valve seat runout Repair
Engine knocks when cold Excessive piston to wall clearance Replace pistons
Loose or broken damper pulley Tighten or replace
Knock increases with torque Excessive piston to bore clearance Replace
Bent connecting rod Replace
Engine has heavy knock when Broken damper pulley Replace
hot and torque is applied
Accessory belts too tight or damaged Adjust or replace belt
Belt tensioned damaged Replace
Flywheel cracked or loose clutch plate Replace flywheel or clutch plate
Excessive main bearing clearance Repair
Excessive rod bearing clearance Repair
Engine has light knock when Improper timing Check timing
hot and under light load
Piston pin and/or connecting rod Replace piston pin and/or rod
conditions
Use recommended or highter
Poor quality fuel
grade fuel
Tighten bolts and/or replace
Exhaust leak at manifold exhaust manifold gasket if
necessary
Excessive rod bearing clearance Repair
Engine knocks during initial
Install proper oil viscosity for
start up and lasts only a few Improper oil viscosity
expected temperatures
seconds

Timing belt

Problem Possible cause Action

Inspect camshaft by removing
Tooth is broken or cracked Camshaft jamming cylinder head cover
Repair or replace if necessary
Back surface is cracked and/or Remove tensioner and inspect
Tensioner jamming
worn Replace if necessary
Inspect cooling system
Engine overheating
Refer to engine cooling system
Remove timing belt cover and
Interference with timing belt cover inspect
Replace if necessary
Side surface is worn and/or Remove timing belt and
Improper installation of timing belt
frayed reinstall
Remove timing belt and inspect
Malfunction of timing belt guide plate
guide plate
Teeth are worn Remove timing belt cover and
Poor belt cover sealing inspect
Replace if necessary
Inspect water pump
Coolant leak at water pump
Replace if necessary
Inspect camshaft removing
Camshaft malfunction cylinder head cover
Repair or replace if necessary
Remove tensioner spring and
Excessive belt tension inspect
Replace if necessary
Oil or coolant is on the belt Inspect front oil seals
Poor sealing
Replace if necessary
Inspect front oil seals
Coolant leak at water pump
Replace if necessary
Remove timing belt cover and
Poor belt cover sealing inspect
Replace if necessary

HLA(Hydraulic lash adjuster)

Problem Possible cause Action

1. Noise when engine is started Run engine at 2,000~3,000 rpm.
immediately after oil is changed. If noise stops after 2 seconds-
Oil leakage in Oil passage
2. Noise when engine is started after 10minutes*, HLA is normal
approx. one day. If not, replace HLA
3. Noise when engine started after * Time required for engine oil to
cranking for 3 seconds or more. circulate within engine includes
Oil leakage in HLA tolerance for engine oil condition
4. Noise when engine is started after
new HLA is installed and ambient temperature.

5. Noise continues more than 10 Check oil pressure.

minutes If lower than specification, check
for cause.
Insufficient oil pressure
Oil pressure : 313.9~490.5 kPa
(3.2~5.0kg/cm²,
45~7.1psi)-3,000rpm
Pressure down HLA by hand.
If it dose not move, HLA is
normal.
Faulty HLA If it moves, replace HLA.
Measure valve clearance.
If more than 0mm(0 in.), replace
HLA.
6 Noise during idle after high-speed Check oil level.
Incorrect oil amount
running Drain or add oil as necessary.
Check oil quality.
Deteriorated oil If deteriorated, replace with
specified type and amount of oil.
Lubrication system

Problem Possible cause Action

Engine hard starting Improper engine oil Replace
Insufficient engine oil Add oil
Excessive oil consumption Internal engine wear Refer to Section Engine
Oil leak Repair
Oil pressure drop Insufficient oil Add oil
Oil leakage Repair
Worn and/or damaged pump gear Replace
Worn plunger (inside oil pump) or weak
Replace
spring
Clogged oil strainer Clean
Excessive main bearing or connecting rod
Refer to section Engine
bearing clearance
Warning lamp illuminates while Oil pressure drop As described above
engine is running
Malfunction of oil pressure switch Refer to Wiring Diagram
Malfunction of electrical system Refer to Wiring Diagram

Cooling system

Problem Possible cause Action

Overheating Coolant level insufficient Add
Coolant leakage Repair
Radiator fins clogged Clean
Radiator cap malfunction Replace
Fan motor malfunction Replace
Thermostat malfunction Replace
Water passage clogged Clean
Water pump malfunction Replace
Corrosion Impurities in coolant Replace
 2000 > 2.5L GASOLIN(K5) >

SPECIFICATION

Engine model
KV6 DOHC
Item
Type Gasoline, 4 cycle
Cylinder arrangement and number 90°-V type, 6 cylinder
Combustion chamber Pentroof
Valve system DOHC, belt driven 24 valve
Displacement 152.4cu-in (2497cc)
Bore and stroke 3.5×3.26in (80×82.8mm)
Compression ratio 10.4 : 1
Compression pressure 191.9 (1324, 13.5)-290)
Valve timing IN Open 2°
Close 54°
EX Open 50°
Close 14°
Valve clearance IN 0 : Maintenance-free
EX 0 : Maintenance-free
Idle speed *1 725 ± 50rpm
Ignition timing *2 12° ± 5° BTDC
Firing order 1-6-5-4-3-2

*1 "P" range position

*2 Test terminal ground
Lubrication system

Engine model
KV6 Gasline
Item
Lubrication system Force-fed type
Oil pump Type Duocentric gear
Relief pressure 49.8~66.9psi (343~441kPa, 3.5~5.4kg/cm²)
Oil filter Type Full-flow, paper element
Relief pressure differential 11.4~17.1psi (78~118kPa, 0.8~1.2kg/cm²)
Oil pressure switch activation pressure 2.8~4.9psi (20~34kPa, 0.2~0.35kg/cm²)
Oil capacity Total (dry engine) 6.13Us qt (5.8liter, 5.1lmp qt)
Oil pan 5.28Us qt (5.0liter, 4.4lmp qt)
Oil filter 0.42Us qt (0.4liter, 0.35lmp qt)
Engine oil APL service SG or SH, SAE 7.5W-30 or 10W-30

Cooling system
 Engine model
KV6 Gasoline
Item
Cooling system Water-cooled, forced circulation
Coolant capacity 9.93 Us qt(9.4liter, 8.27lmp qt)
Water pump Type Centrifugal
Thermostat Type Wax (Bottom by-pass)
Initial opening
178.7~184.1°F (81.5~84.5°C)
temperature
Full-open temperature 204.8°F (96°C)
Full-open lift 0.35in (9.0)minimum
Radiator Type Corrugated fin
Cap valve opening
10.7~14.9Psi (73.6~103.0kPa, 0.75~1.05kg/cm²)
pressure
Cooling fan Type Electric
Above 208.7°F (98°C)-Low speed
Operating temperature
Above 221°F (105°C)-High speed
Number of blades 5
Outer diameter 14.4in (366mm)

Intake and exhaust system

Engine
KV6 Gasoline
Item
Air cleaner
Dried
Element type
Accelerator cable
0.04~0.11in (1~3mm)
Free play
 Engine Mechanical System

Engine Mechanical System

Timing System - Timing Belt

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENT
 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Disconnect negative battery cable.
2. Remove two nuts and three bolts.
Remove No. 3 engine mounting bracket.

3. Raise drive belt tensioner with spanner and then remove drive belt.

4. Remove three bolts securing power steering pump.

Remove power steering pump and reserve tank with hoses still connected.
5. Position power steering pump and reserve tank away from engine and affix it with wire.

6. Disconnect B-terminal and connector from alternator.

7. Remove two bolts and release alternator from mounting bracket. Remove alternator0
8. Remove two bolts securing drive belt idler and remove idler.
9. Remove bolt securing oil level gauge pipe to cylinder head.
10. Remove two nuts securing oil level gauge pipe to oil pan. Remove oil level gauge pipe and discard gasket.
11. Remove three bolts and remove front timing belt LH cover.
12. Remove three bolts and remove front timing belt RH cover.
13. Remove five bolts securing alternator/power steering pump mounting bracket.
14. Remove mounting bracket and engine lifting bracket.
15. Remove two bolts securing drive belt tensioner and remove tensioner.
16. Set engine in timing mark position. To do this turn crankshaft in a clockwise direction until "L" mark on
camshaft pulley of LH bank positions to mark on timing back plate.

17. Raise and properly support vehicle.

18. Remove five nuts and remove wheel & tire.
19. Remove two bolts and three faster securing mud guard of wheel house. Remove mud guard.

20. Remove crankshaft pulley bolt.

21. Remove crankshaft pulley.
22. Remove three bolts securing crankshaft pulley cover and remove cover.
23. Remove four bolts securing air conditioner compressor.
Remove compressor with hoses still connected.
24. Position compressor away from engine and affix it with wire.

25. Remove four bolts securing air conditioner compressor bracket and remove bracket.
26. Remove bolt securing harness clip to front cover.
27. Remove six bolts securing front cover to engine block.
28. Remove Allen bolt securing front cover to engine block.
29. Remove front cover.
30. Remove upper bolt securing timing belt auto tensioner to engine block.

31. Slacken lower bolt and allow timing belt auto tensioner to swing away from timing belt auto tensioner pulley
assembly.
32. Remove front timing belt.

• Ease timing belt off gears using fingers only : levers may damage band gears.
• Do not turn crankshaft with timing belt removed and cylinder heads fitted.

INSTALLTION
1. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
Check that "L" mark on camshaft pulley of LH bank is aligned with mark on timing belt back plate.
Check that "R" mark on camshaft pulley of RH bank is aligned with mark on timing belt back plate.

2. Using fingers only, install timing belt to pulleys, starting at timing belt pulley and working on
counterclockwise direction, keeping run as taut as possible.

Arrow mark of timing belt must be matched driving direction.

3. Using a press, slowly compress auto-tensioner rod and install a suitable pin 0.08in (2.0mm) ib diameter to
retain rod.
4. Position tensioner, fit bolts and tighten.

Tightening torque :
A : 15.9~18.8lb-ft (22~25N·m, 2.2~2.4kg-m)
B : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)

5. Release auto-tensioner pulley and remove pin from auto-tensioner.

6. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing
mark on engine block.
7. Check that "L" mark on camshaft pulley of LH bank is aligned with mark on timing belt back plate.
Check that "R" mark on camshaft pulley of RH bank is aligned with on timing belt back plate.

8. If they are not aligned, remove timing belt and repeat from step 1 to step7.
9. Install front cover.

Tightening torque
1 : 20.9~26.0lb-ft (28~35N·m, 2.9~3.6kg-m)
5 : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)
2, 3, 4, 6, 7 : 55.6~66.6lb-ft (75~90N·m, 7.7~9.2kg-m)

10. Install harness clip to front cover.

11. Install air conditioner compressor bracket.

Tightening torque : 27.5~39.1lb-ft (37~53N·m, 3.8~5.4kg-m)

12. Install air condition compressor.

13. Install crank-shaft cover.
 Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

14. Install crankshaft pulley.

Tightening torque : 115~123lb-ft (157~167N·m, 16~17kg-cm)

15. Install mud guard of wheel house.

16. Install wheel & tire.

Tightening torque : 65~79lb-ft (88~107N·m, 9~11kg-m)

17. Install drive belt tensioner.

Tightening torque : 15.9~20.3lb-ft (22~27N·m, 2.2~2.8kg-m)

18. Install alternator/power steering pump mounting bracket.

Tightening torque : 33.3lb-ft (45N·m, 4.61kg-m)

19. Install front timing belt LH and RH covers taking care not to displace seals.

Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

20. Install oil level gauge pipe using new gasket and tighten nuts and bolt.

Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

21. Install drive belt idler.

Tightening torque : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)

22. Install alternator to mounting bracket.

Tightening torque : 33.3lb-ft (45N·m, 4.6kg-m)

23. Reconnect alternator B-terminal and connector to alternator.

24. Install power steering pump to mounting bracket.
25. Raise drive belt tensioner with spanner and then install drive belt.

26. Install No.3 engine mounting bracket.

 Tightening torque : 49.2~68.7lb-ft (66.6~93.1N·m, 6.8~9.5kg-m)

27. Reconnect negative battery cable.

INSPECTION

Never forcefully twist, turn inside out or bent timing belt. Do not allow oil or grease to come in contact with
timing belt.

1. Replace timing belt if ir contaminated with oil or grease.

2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as
necessary.

3. Bend timing belt into a "U" shapes as shown in figure. Distance "A" must be at least 1.0in (25mm).
4. Inspect both idler pulley and auto-tensioner pulley for uneven wear and smooth bearing operation.

5. Check auto-tensioner for oil leakage. Replace auto-tensioner if necessary.

6. Measure auto-tensioner rod projection. Replace auto-tensioner if necessary.

Projection (Free length) : 0.55 in (14mm)

7. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.

Replace any component that shows damage, excessive wear or that appears prone to a possible
failure.

DISASSEMBLY
1. Install SST(OK552 101 001) to engine.
2. Mount engine on engine stand (OK130 990 007).

3. Hold drive plate (ATX) with SST (OK590 111 001).

4. Remove pulley lock bolt. Remove crankshaft pulley.

5. Remove three bolt securing crankshaft pulley cover and remove cover.
6. Remove three bolts securing power steering pump.
Remove power steering pump from mounting bracket.
7. Disconnect B-terminal and connector from alternator.
8. Remove two bolts and release alternator fro, mounting bracket. Remove alternator.
9. Remove two bolts securing drive belt idler and remove idler.
10. Remove bolt securing oil level gauge pipe to cylinder head.
11. Remove two nuts securing oil level gauge pipe to oil pan. Remove oil level gauge pipe and discard gasket.
12. Remove three bolts and remove front timing belt LH cover.
13. Remove three bolts and remove front timing belt RH cover.
14. Remove five bolts securing alernator /power steering pump mounting bracket.
15. Remove mounting bracket and engine lifting bracket.
16. Remove two bolts securing drive belt tensioner and remove tensioner.
17. Remove six bolts securing front cover to engine block.
18. Remove Allen bolt securing front cover to engine block.
19. Remove front cover.
20. Remove upper bolt securing timing belt.
21. Loosen camshaft pulley lock bolt.
22. Slacken lower bolt and allow timing belt auto tensioner to swing away from belt auto tensioner pulley
 assembly.
23. Remove timing belt.

• Ease timing belt off gears using fingers only : levers may damage belt and gears.
• Do not turn crankshaft with belt removed and cylinder heads fitted.

24. Remove timing belt idler.

25. Remove auto-tensioner pulley.
26. Remove front camshaft pulley.
27. Remove front timing belt back plate.

REASSEMBLY
1. Install front cover.

Tightening torque :
1 : 20.9~26.0lb-ft (28~35N·m, 2.9~3.6kg-m)
5 : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)
2, 3, 4, 6, 7 : 55.7~66.6lb-ft (75~90N·m, 7.7~9.2kg-m)

2. Install alternator/power steering pump mounting bracket and engine lifting bracket.

Tightening torque : 33.3lb-ft (45N·m, 4.61kg-m)

3. Install front timing belt LH and RH covers taking care not to displace seals.

Tightening torque : 3.6~5.0lb-ft (5~7N·m, 0.5~0.7kg-m)

4. Install oil level gauge pipe using new gasket and tighten nuts and bolt.

Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

5. Install drive belt idler.

Tightening torque : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)

6. Install alternator to mounting bracket.

Tightening torque : 33.3lb-ft (45N·m, 4.6kg-m)

7. Reconnect alternator B-terminal and connector to alternator.

8. Install power steering pump to mounting bracket.
9. Install crankshaft pulley cover.

Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

10. Install crankshaft pulley.

Tightening torque : 5.2~7.4lb-ft (7~10N·m, 71.4~102kg-cm)

 Engine Mechanical System

Engine Mechanical System

Cylinder Head Assembly - Camshaft

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
1. Set front and rear journals on V-blocks.
2. Measure camshaft runout. Replace camshaft if necessary.

Runout : 0.0012in (0.03mm) max.

3. Inspect camshaft for wear or damage. Replace camshaft if necessary.

4. Measure cam lobe height at two points as shown.

Cam height
Standard :
Intake-1.5169in (38.53mm)
Exhaust-1.5401in (39.12mm)
Minimum :
Intake-1.5149in (38.48mm)
Exhaust-5393in (39.10mm)

5. Measure journal diameters in X and Y directions at two points (A and B)shown.

Journal diameter
Intake : 1.1799~1.1811in (29.97~30.00mm)
Exhaust : 1.1799~1.1811in (29.97~30.00mm)

6. Measure camshaft journal oil clearances.

 Do not install HLA when measuring oil clearance.

(1) Remove all foreign material and oil from journals and bearing surface.
(2) Set camshaft onto cylinder head.
(3) Position Plastigage atop journals in axial direction.
(4) Install camshaft carrier and tighten in order shown in figure.

Tightening toque : 5.16~7.38lb-ft (7~10N·m, 71.4~102kg-cm)

(5) Loosen camshaft carrier bolts in reverse order of tightening.

(6) Measure oil clearance at each journal.

Oil clearance : 0.00098~0.00232in (0.025~0.059mm)

(7) If oil clearance exceeds maximum, replace camshaft and/or cylinder head.
 Engine Mechanical System

Engine Mechanical System

Valve

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENT
 2000 > 2.5L GASOLIN(K5) >

REMOVAL
Cylinder head gasket
1. Disconnect negative battery cable.
2. Drain engine coolant.

3. Drain engine oil.

4. Remove rear timing belt back plate from cylinder head.
(Refer to HLA Removal(RH bank) from step 2 to step 25)
5. Remove two bolts securing coolant upper hose.

6. Disconnect cam position sensor connector and O² sensor connector.

7. Disconnect ignition coil connector, fuel injector connector and intake air temperature sensor connector.

8. Disconnect fuel hose from injector rail.

KEEP OPEN FRAMES AND SPARKS AWAY FROM OPEN FUEL LINES, OR A FIRE OR EXPLOSION
MAY RESULT.

9. Disconnect coolant hose.

10. Remove intake manifold with 5 bolts and 2 nuts.
11. Remove exhaust manifold.
12. Remove camshaft cover.
13. Remove cylinder head.

14. Replace cylinder head gasket.

INSTALLATION
1. Thoroughly clean cylinder block and cylinder head mating faces.
2. Ensure locating dowels are correctly positioned in cylinder block.
3. Place new cylinder head gasket onto block face with word "TOP" uppermost.
4. Install cylinder head and locate onto dowels.
5. Carefully enter cylinder head bolts. Screw bolts into place by hand.

Do not drop cylinder head bolts.

6. Apply engine oil to bolt threads and seat faces.

7. Tighten cylinder head bolts in two or three steps on order shown in figure.

Tightening torque :
Pretighten 18.8lb-ft (25N·m, 2.6kg-m) and then tighten 90°.
Retighten 26~33lb-ft (35~45N·m, 3.6~4.6kg-m)

8. Clean mating surface of camshaft cover and camshaft carrier.

9. Clean inside of camshaft cover.
10. Install camshaft cover gasket and position camshaft cover to camshaft carrier.
 When installing new camshaft cover gasket ensure arrows point towards inlet manifold.

11. Tighten camshaft cover bolts in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

12. Install exhaust manifold.

13. Install intake manifold.

14. Reconnect coolant hose.

15. Reconnect fuel hose to injector rail.
16. Reconnect ignition coil connector, fuel injector connector and intake air-temperature sensor connector.
17. Reconnect cam position sensor connector and O² sensor connector.
18. Install coolant upper hose.
19. Install No. 3 engine mounting bracket.
(Refer to HLA Installation (RH bank), from step 15 to 40)
20. Fill engine with specified amount and type of engine oil.
(Refer to Lubrication system)
21. Fill engine with specified amount and type of coolant.
Refer to Cooling system)
22. Connect negative battery cable.

INSPECTION
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.
3. Measure cylinder head for straightness in six directions shown in figure.

4. If distortion exceeds specification, resurface or replace cylinder head. Only remove amount of material
required to achieve a flat surface.

Maximum material removal : 0.006in (0.15mm)

5. Check cylinder head height.

Height : 4.683~4.687in (118.95~119.05mm)

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 mounting
surface for straightness.

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

Distortion : 0.006in (0.15mm)

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

 Maximum material removal : 0.006in (0.15mm)

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

Distortion : 0.006in (0.15mm)

10. If distortion exceeds specification, resurface block deck.

Maximum material removal : 0.006in (0.15mm)

INSPECTION
1. Inspect cylinder head for damage, cracks, and leakage of water and oil. Replace cylinder head of
necessary.
2. Measure cylinder head distortion in six directions shown in figure.

Distortion : 0.006in (0.15mm)

Before grinding cylinder head, check following and repair or replace cylinder head if necessary.
• Sinking valve seats
• Damage of manefold contact surface
• Camshaft oil clearance and end play

3. If cylinder head distortion exceeds specification, grind cylinder head surface.

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

Height : 4.683~4.687in (118.95~119.05mm)

Grinding : 0.006in (0.15mm) max.

4. Measure manifold contact surface distortion in two directions shown in firgre.

5. If distortion exceeds specification grind surface of replace cylinder head.

DISASSEMBLY
1. Disconnect TPS and ISC valve connector.

2. Disconnect breather hose from throttle body.

3. Remove high tension cords.
4. Disconnect breather hoses from LH camshaft cover.
5. Disconnect breather hose and fuel return hose at surge tank.

6. Remove surge tank with four bolt and two nuts.

7. Disconnect ignition coil connector.

8. Disconnect fuel injector connector.
9. Remove ignition coil assembly with five bolts.
10. Remove fuel line.
11. Remove rear timing belt cover with three bolts.
12. Remove rear timing belt tensioner.

Replace tensioner spring whenever timing belt is replaced.

13. Remove rear timing belt.

14. Remove rear camshaft pulleys.
15. Remove two bolts and remove rear timing belt back plate from cylinder head.
16. Remove fourteen bolts and remove camshaft cover and gasket.
17. Using sequence shown, progressively slacken twenty two bolts securing camshaft carrier to cylinder head
until valve spring pressure is released. Remove bolts.

18. Remove camshaft carrier.

Carrier is located by dowels.

19. Remove camshafts and discard oil seals.

20. Mark HLA's to identify their original position if they will be reused.

Hydraulic Lash Adjusters(HLA) must be installed in location from which they were removed. Failure to
install HLA's in their original location will result in premature and uneven wear of HLA's and camshafts.

21. Using a magnet, remove twenty four HLA's from cylinder head.
22. Store HLA's upside-down in an oil-filled container.
23. Loosen cylinder head bolts in two or three steps following order shown in figure.

24. Remove cylinder head by lifting if off from cylinder block.

25. Compress valve springs with SST (OK993 120 001) and allow enough room to remove valve cotters.

26. Slowly release pressure and remove upper seat/valve spring from cylinder head.
27. Repeat same procedure on all 24 valves.
28. Keep valves in correct order if they are to be reused.
29. Mark cylinder head so that valves can be installed to their original positions.
30. Remove valves from cylinder head.

RESSAEMBLY
1. Check that valve guide projection height (dimension A in figure). Replace if necessary.

Height : 0.236in (6mm)

2. Install valve, then slide valve seal over valve stem and onto valve guide.
3. Install valve seat installer over seal.
 Using a hammer will damage valve seals.

4. Install lower spring seat on cylinder head.

5. Install valve spring and upper spring seat.
6. Compress valve spring with SST : then install valve cotters.

7. Tap end of valve stem lightly two or three with a plastic hammer to confirm that cotters are fully seated.
8. Thoroughly clean cylinder block and cylinder head mating faces.
9. Ensure locating dowels are correctly position in cylinder block.
10. Place new cylinder head gasket onto block face with word "TOP" uppermost.
11. Install cylinder head and locate onto dowels.
12. Carefully enter cylinder head bolts. Screw bolt into place by hand.

Do not drop cylinder head bolts.

13. Apply engine oil to bolt threads and seat faces.

14. Tighten cylinder head bolts in two or three steps in order shown in firgure.

Tighten torque
Pretighten 18.8lb-ft (25N·m, 2.6kg-m) and then tighten 90°.
Retighten 26~33lb-ft (35~45N·m, 3.6~4.6kg-m).

15. Apply a coat of clean engine oil friction surface of HLA.

16. Install HLA into cylinder head bore.

If HLA is being reused, install it in its original position.

17. Check that HLA moves smoothly in its bore.

18. Inspect cams and replace camshaft if scored, pitted or excessively worn.
19. Apply clean engine oil to camshaft and camshaft bearing surfaces and install camshaft.
20. Using plastic scraper from sealing kit, clean sealing surfaces on cylinder head and camshaft carrier.
Clean sealing surfaces using Hylomar Easy Clean solvent and line-free cloth.

Do not use a metal scraper.

21. Apply contiunous thin beads of sealant to paths on camshaft carrier as shown then spread to an even film
using a brush or roller.

Sealant : Hylogrip 2000

Bead width : 0.079in (2mm)

Ensure sealant is kept clear of HLA oil feed holes and lubrication grooves in carrier and that assembly
is completed within 15 minutes.

22. Install oil seal to camshaft.

23. Apply engine oil to cams and journals.
24. Install camshaft carrier and tighten bolts in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

25. Clean mating surface of camshaft cover and camshaft carrier.
26. Clean inside of camshaft cover.
27. Install camshaft cover gasket and position camshaft cover to camshaft carrier.

When installing new camshaft cover gasket ensure arrows point towards inlet manifold0

28. Tighten camshaft cover bolt in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

29. Install front timing belt back plate and rear timing belt back plate to cylinder head.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

30. Install front camshaft pulley as shown as shown in figure.

Tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-cm)

31. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
Check that "L" mark on camshaft pulley of LH bank is aligned with mark on timing belt back plate.
Check that "R" mark on camshaft pulley of RH bank is aligned with mark on timing belt back plate.
32. Using fingers only, install timing belt to pulleys, starting of timing belt pulley and working in
counterclockwise direction, keeping run as taut as possible.

Arrow mark of timing belt must be matched driving direction.

33. Using a press, slowly compress auto-tensioner rod and install a suitable pun, 0.08in (2.0mm) in diameter to
retain rod.

34. Position tensioner, fit bolts and tighten.

Tightening torque
A : 15.9~18.8lb-ft (22~25N·m, 2.2~2.4kg-m)
B : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)

35. Release auto-tensioner pulley and remove pin from auto-tensioner.

36. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with
timing mark on engine block.
37. Check that "L" mark on camshaft pulley of LH bank is aligned with mark on timing belt back plate.
Check that "R" mark on camshaft pulley of RH bank is aligned with mark on timing belt back plate.
38. If they are not aligned, remove timing belt and repeat from step 30 to step 37.
39. Install rear camshaft pulley. For intake camshaft pulley of RH bank, set "B" mark to dowel pin of camshaft
and verifly that "A" mark points upward.
For intake pin of camshaft and verify that "A" mark to dowel pin of camshaft and verify that "A" mark points
upward.

40. For exhaust camshaft pulley, set "A" mark to dowel pin of camshaft and line up "A" mark to indicatior on
rear back plate at both bank.

Ensure cam pulley flange direction.

Pulley lock bolt tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-m)

41. Finger tighten rear timing belt tensioner.

Replace tensioner spring whenever timing belt is replaced.

42. Install rear timing belt.

43. Turn crankshaft 90° to clockwise for tensioner spring setting and then tighten tensioner lock bolt.

Tensioner lock bolt tightening torque : 26.72~38.33lb-ft (37~52N·m, 3.7~5.3kg-m)

44. Measure tension at arrow mark indicated in figure with clavis gauge.

Tension : 100~140Hz

45. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with
timing mark on engine block.
46. Verify if timing mark of front and rear camshaft pulleys aligned proper position.

47. Install rear timing belt cover.

Tightening torque : 2.2~2.5lb-ft (3~5N·m, 0.3~0.35kg-cm)

48. Install intake manifold.

49. Install fuel line.
50. Install ignition coil assembly.
51. Reconnect fuel injector connector.
52. Reconnect ignition coil connector.
53. Install surge tank.
54. Reconnect breather hose and fuel return hose to surge tank.
55. Reconnect breather hose from LH camshaft cover.
56. Install high tension cords.
57. Reconnect breather hose to throttle body.
58. Reconnect TPS and IAC sensor connectors.
 Engine Mechanical System

Engine Mechanical System

Cylinder Head

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
Valve and valve guide
1. Inspection each valve for following.
Replace or resurface if necessary.
(1) Damage or bent stem
(2) Roughness or damage to face
(3) Damage or uneven wear of stem tip

2. Check valve head margin thickness. Replace if necessary.

Margin thickness
Intake : 0.0519~0.0622in (1.32~1.58mm)
Exhaust : 0.0716~0.0818in (1.82~2.08mm)

3. Measure valve length.

Valve length :
Standard :
Intake-3.527in (89.6mm)
Exhaust-3.543in (90.0mm)
Minimum :
Intake-3.519in (89.39mm)
Exhaust-3.535in (89.81mm)

4. Measure valve stem diameter.

Diameter
Instake : 0.2343~0.2349in (5.952~5.957mm)
Exhaust : 0.2341~0.2347in (5.947~5.942mm)
5. Measure valve guide inner diameter.

Inner diameter Intake, Exhaust : 0.2362~0.2372 in(6.000~6.025mm)

6. Measure valve stem to guide clearance by subtract outer diameter of valve stem from inner diameter of
corresponding valve guide.

Clearance
Intake : 0.00098~0.00236in (0.025~0.060mm)
Exhaust : 0.00118~0.00255in (0.030~0.065mm)

7. If clearance exceeds maximum, replace valve and/or valve guide.

8. Check that valve guide projection height (dimension A in figure). Replace if necessary.

Height : 0.236in (6mm)

Valve seat
1. Inspect contact surface of valve seat and valve face for following
 A. Roughness
B. Damage
2. If necessary resurface valve seat with a 45° valve seat cutter and/or resurface valve face.

3. Apply a thin coat of prussian blue to valve face.

4. Check valve seating by rotating valve against seat.
(1) If blue dose not appear 360° around valve face.
(2) If blue dose not appear 360° around valve seat resurface valve.

5. Check seat contact width.

Width : 0.047~0.67in (1.2~1.7mm)

6. Check that valve seating position is at center of valve face.

(1) If seat position is too high, correct valve seat with a 45° cutter.
(2) If seat position is too low, correct valve seat with a 45° cutter.

7. Seat valve to valve seat with a lapping compound.

Valve spring
1. Inspect each valve spring for cracks or damage.
2. Check free length and out-of-square. Replace if necessary.

Free length : 1.874in (47.6mm)

Out-of-square : 0.056in (1.43mm)

Free length : 1.874in (47.6mm)

3. Check spring pressure when length of spring is 1.45in (37mm), replace it if necessary.
 Engine Mechanical System

Engine Mechanical System

HLA (Hydraulic Lash Adjuster)

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENTS

HLA bank

LH bank
 2000 > 2.5L GASOLIN(K5) >

REMOVAL
RH bank
1. Disconnect negative battery cable.
2. Remove front cover.
(Refer to Front Timing belt removal : from step 1 tp step 28)
3. Remove fresh air-duct with two bolts and clamp.

4. Disconnect air flow sensor connector.

5. Remove air cleaner assembly with three bolts and clamp.
6. Remove accelerator cable.

7. Disconnect TPS and IAC valve connectors.

8. Disconnect breather hose from throttle body.
9. Remove high-tension cords.
10. Disconnect breather hoses from LH camshaft cover.

11. Disconnect breather hose and fuel return hose at surge tank.
12. Remove harness coupler bracket from surge tank.

13. Disconnect VICS valve connector, brake vacuum hose and purge control vacuum hose.

14. Remove surge tank with four bolts and two nuts.
15. Remove rear timing belt cover with three bolts.
16. Slacken front camshaft pulley bolt and rear camshaft pulley bolts.
17. Remove upper bolt securing front timing belt auto-tensioner to engine block.

18. Slacken lower bolt and allow front timing belt auto-tensioner to swing away from timing belt auto tensioner
pulley assembly.
Remove bolt and remove auto-tensioner.
19. Remove front timing belt.

• Ease timing belt off gears using fingers only : levers may damage belt and gears.
• Do not turn crankshaft with timing belt removed and cylinder heads fitted.

20. Remove front camshaft pulley.

21. Remove four bolt and remove front timing belt back plate from cylinder head.
22. Remove rear timing belt tensioner.
 Replace tensioner spring whenever timing belt is replaced.

23. Remove rear timing belt.

24. Remove rear camshaft pulleys.
25. Remove two bolts and remove rear timing belt back plate from cylinder head.
26. Remove fourteen bolts and remove camshaft cover and gasket.
27. Using sequence shown, progressively slacken twenty two bolts securing camshaft carrier to cylinder head
until valve spring pressure is released. Remove bolts.

28. Remove camshaft carrier.

Carrie is located by dowels.

29. Remove camshafts and discard oil seals.

30. Mark HLA's to identify their original position if they will be reused.

Hydraulic Lash Adjusters(HLA) must be installed in location from which they were removed. Failure to
install HLA's in their original location will result in premature and uneven wear of HLA's and camshafts.

31. Using a magnet, remove twelve HLA's from cylinder head.

32. Stroe HLA's upside-down in an oil-filled container.
 REMOVAL
LH bank
1. Disconnect negative battery cable.
2. Remove front cover.
3. Remove fresh air-duct with two bolts and clamp.

4. Disconnect air flow sensor connector.

5. Remove air cleaner assembly with three bolts and clamp.
6. Remove high-tension cords.
7. Disconnect breather hoses from LH camshaft cover.

8. Remove two bolts securing coolant upper hose.

9. Disconnect cam position sensor connector and O² sensor connector.
10. Remove twelve HLA's from cylinder head.

INSTALLATION
RH bank
1. Apply a coat of clean engine oil to friction surface of HLA.

2. Install HLA into cylinder head bore.

If HLA is being reused, install it in its original position.

3. Check that HLA moves smoothly in its bore.

4. Inspect cams and replace camshaft if scored, pitted or excessively worn.
5. Apply clean engine oil to camshaft and camshaft bearing surface and install camshaft.
6. Using plastic scraper from sealing kit, clean sealing surfaces on cylinder head and camshaft carrier.
Clean sealing surfaces using Hylomar Easy Clean solvent and lint-free cloth.

Do not use a metal scraper.

7. Apply continuous thin beads of sealant to paths on camshaft carrier as shown then spread to an even film
using a brush or roller.

Sealant type : Hylogrip 2000

Bead width : 0.079in (2mm)

Ensure sealant is kept clear of HLA oil feed holes and holes and lubrication grooven in carrier and that
assembly is completed within 15minutes.

8. Install oil seal to camshafts.

9. Apply engine oil to cams and journals.
10. Install camshaft carrier and tighten bolts in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

11. Clean matinf surface of camshaft cover and camshaft carrier.

12. Clean inside of camshaft cover.
13. Install camshaft cover gasket and position camshaft cover to camshaft carrier.

When installing new camshaft cover gasket ensure arrows point towards inlet manifold.

14. Tighten camshaft cover bolts in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

15. Install front timing belt back plate and rear timing belt plate to cylinder head.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

16. Install front camshaft pulley as shown in figure.

Tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-cm)

17. Install front timing belt.

(Refer to Front timing belt Installation : from step 1 to step 5)
18. Install rear camshaft pulley. For intake camshaft pulley of RH bank, set "B" mark to dowel pin of camshaft
and verify that "A" mark points upward.

19. For exhaust camshaft pulley, set "A" mark to dowel pin of camshaft and line up "A" mark to indicator on
rear back plate at both bank.

Ensure cam pulley flange direction.

Pulley lock tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-m)

20. Finger tighten rear timing belt tensioner.

 Replace tensioner spring whenever timing belt is replaced.

21. Install rear timing belt.

22. Turn crankshaft 90° to clockwise for tensioner spring setting and then tighten tension lock bolt.

Tensioner lock bolt tightening torque : 26.76~38.33lb-ft (37~52N·m, 3.7~5.3kg-m)

23. Measure tension at arrow mark indication in figure with clavis gauge.

Tension : 100~140Hz

24. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with
timing mark on engine block.
25. Verify if timing mark of front and rear camshaft pulley aligned proper position.
26. Install rear timing belt cover.

Tightening torque : 2.2~3.6lb-ft (3~5N·m, 0.3~0.5kg-cm)

27. Install surge tank.

28. Connect VICS valve connector, broken vacuum hose and purge control vacuum hose.
29. Install harness coupler bracket to surge tank.
30. Connect breather hose and fuel return hose to surge tank.
31. Connect breather hose to camshaft cover.
32. Install high-tension cords.
33. Connect breather hose to throttle body.
34. Connect TPS and IAC sensor connectors.
35. Install accelerator cable.
36. Measure free play of accelerator cable.

Free play : 0.04~0.11 in (1~3mm)

37. Install air clean assembly.

38. Connect air flow sensor connector.
39. Install fresh sensor connector.
40. Install No. 3 engine mounting bracket.
41. Connect negative battery cable.

INSTALLATION
LH bank
1. Install camshaft cover.
2. Tighten camshaft cover bolts in order shown in figure.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

3. Install front timing belt back plate and rear timing belt back plate to cylinder head.

Tightening torque : 5.164~7.377lb-ft (7~10N·m, 71.4~102kg-cm)

4. Install front camshaft pulley as shown in figure.

Tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-cm)

5. Install front belt.

6. Install rear camshaft pulley. For intake camshaft pulley of LH bank, set "A" mark to dowel pin of camshaft
and verify that "A" mark point upward.
7. For exhaust camshaft pulley, set "A" mark to dowel pin of camshaft and line up "A" mark to indicator on rear
back plate at both bank.

Ensure cam pulley flange direction.

Pulley lock bolt tightening torque : 36.16~44.84lb-ft (49~61N·m, 5.0~6.2kg-m)

8. Install rear timing belt cover.

9. Connect cam position sensor connector and O² sensor connector.
10. Install bolts securing coolant upper hose.
11. Connect breather hoses to LH camshaft cover.
12. Install high-tension cords.
13. Install air clean assembly.
14. Connect air flow sensor connector.
15. Install fresh air-duct.
16. Install No. 3 engine mounting bracket.
17. Connect negative battery cable.
 Engine Mechanical System

Engine Mechanical System

Engine And Transaxle Assembly

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENTS
 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Disconnect negative battery cable.
2. Raise and properly support vehicle.
3. Drain engine coolant (Refer to section Cooling system).
4. Drain ATF.

5. Raise an auto tensioner with spanner and then remove drive belt.

6. Remove two hoses from reserve tank.

7. Remove hoses from power steering pump.

8. Remove A/C compressor with hoses still connected.

9. Position A/C compressor away from engine and affix it with wire.

10. Remove flash air duct.

11. Remove upper and lower radiator hoses.
12. Remove heater hoses and brake hose.
13. Remove fuel hose. (Refer to section fuel system).
 • BEFORE DISCONNECTING FUEL HOSE, KEEP SPARKS, SIGARTTES, AND OPEN FLAMES
AWAY FROM IT.
• COVER HOSE WITH A RAG BECAUSE FUEL WILL SPRAY OUT WHEN DISCONNECTING.
• PLUG DISCONNECTED HOSES TO AVOID FUEL LEAKAGE.

14. Remove three air cleaner assembly nuts and then remove air cleaner assembly.
15. Remove accelerator cable.
16. Remove U-clip from selector cable to auto transaxle linkage.
17. Remove nut and washer from auto transaxle linkage.

18. Remove three No. 4 engine mounting nuts and then loosen engine mounting bolt.

19. Disconnect solenoid connector.

20. Remove startor motor (Refer to section startor system)
21. Disconnect crank position sensor connector.
22. Disconnect vehicle speed sensor connector.

23. Disconnect two oxygen sensor connectors.

24. Disconnect two ATF cooler hoses.
25. Remove No. 3 engine mounting.
26. Remove both front wheels (five lug nuts each).
27. Remove exhaust manifold (Refer to section intake and exhaust system).
28. Remove both right and left rod ends from steering knuckles by removing a cotter pin and a nut each.
29. Remove stabilizer bracket and then remove control link from stabilizer.
30. Remove control link knuckle.
31. Remove pinch bolt and nut from both right and left knuckles. Separate lower arm from knuckle.

32. Remove joint shaft support bracket from engine block (three bolt).
33. Gently pry both driveshafts from auto transaxle.

34. Remove intermediate shaft bolt (Refer to section steering system).

35. Support auto transaxle, engine and sub frame with a suitable floor jack.

36. Remove four sub frame nuts and four tension rod, nuts and then remove sub frame.
37. Slowly lower engine, auto transaxle and subframe.
38. Remove three No. 1 engine mounting-to-subframe bolts.

39. Remove four No. 2 engine mounting bolts and then remove No. 2 engine mounting from auto transaxle and
subframe.

40. Remove three upper converter housing bolts.

41. Remove six drive plate-to-torque converter mounting nuts. Rotate engine at crank pulley to gain access to
all six nuts.

42. Remove nine remaining converter housing bolts.

43. Gently separate transaxle from engine.

INSTALLATION
1. Install transaxle to engine and then install converter housing bolts.

Tightening torque : 47.0~65.8lb-ft (63.7~89.2N·m, 6.5~9.1kg-m)

2. Install three upper converter housing bolts.

3. Install six drive plate-to-torque converter mounting nuts. Rotate engine at crank pulley to gain access to all
six nuts.

Tightening torque : 25.3~36.1 lb-ft (34.3~49.0N·m, 3.5~5.0kg-m)

4. Install No. 2 engine mounting to auto transaxle then install four bolts.

Tightening torque :
Short bolts : 49.1~68.7lb-ft (66.7~93.1N·m, 6.8~9.5kg-m)
Long bolt : 62.9~86.0lb-ft (85.3~116.7N·m, 8.7~11.9kg-m)
5. Install three No. 1 engine mounting-to-subframe bolts.

Tightening torque : 49.1~68.7lb-ft (66.7~93.1N·m, 6.8~9.5kg-m)

6. Set auto transaxle, engine and sub frame on suitable floor jack and then place under vehicle.
7. Raise auto transaxle, engine and subframe and then align with engine compartment.

8. Install four subframe nuts and four tension rod nuts.

Tightening torque :
Sub frame : 88.2~101.2lb-ft (119.6~137.3N·m, 12.2~14.0kg-m)
Tension rod : 68.7~84.6lb-ft (93.1~114.7N·m, 9.5~11.7kg-m)

9. Remove suitable floor jack from auto transaxle and engine.

10. Install No. 3 engine mounting.

Tightening torque
Nuts : 49.1~68.7lb-ft (66.7~93.1N·m, 6.8~9.5kg-m)
Bolts : 62.9~86.0lb-ft (8.3~116.7N·m, 8.7~11.9kg-m)
11. Install No. 4 engine mounting.

Tightening torque : 49.1~68.7lb-ft (66.7~93.1N·m, 6.8~9.5kg-m)

12. Install intermediate shaft bolt (Refer to section steering system).

13. Install new clips on driveshaft.
14. Push driveshaft and joint shaft into transaxle with opening of pointing upward.
15. Install joint shaft support bracket then install three bolts.

Tightening torque : 31.1~45.5lb-ft (42.1~61.8N·m, 4.3~6.3kg-m)

16. Install right and left lower arm to subframe.

Tightening torque : 88.2~101.2lb-ft (119.6~137.3N·m, 12.2~14.0kg-m)

17. Install both right and left lower arm ball joints into spindle then install pinch bolts.

Tightening torque : 68.7~84.6lb-ft (93.1~114.7N·m, 9.5~11.7kg-m)

18. Install both right and left control links.

Tightening torque : 68.7~84.6lb-ft (93.1~114.7N·m, 9.5~11.7kg-m)

19. Install both right and left tie rod end to steering knuckle then install tie rod end nuts.

Tightening torque : 43.3~58.5lb-ft (58.8~79.4N·m, 6.0~8.1kg-m)

Insert cotter pin and bend over.

20. Install exhaust manifold (Refer to section intake and exhaust system).
21. Install both right and left wheels then tighten both right and left lug nuts (five lug nuts each).

Tightening torque : 65.0~86.7lb-ft (88.2~117.7N·m, 9.0~12.0kg-m)

22. Lower vehicle.

23. Slide ATF innet and outnet onto ATF cooler pipe until it is fully seated again ridge.
24. Install hose clamp onto hose at center of mark and at center of mark and at angle shown.

25. Connect two oxygen sensor connector.

26. Connect vehicle speed sensor connector.

27. Install startor motor (Refer to section startor system).

28. Connect solenoid connector.
29. Connect crank position sensor connector.
30. Install nut to transaxle linkage.
31. Insert U-clip.

32. Install accelerator cable (Refer to section intake and exhaust system).
33. Install fuel hose (Refer to section fuel system).
34. Install heater hoses and brake hose.
35. Install upper and lower radiator hose.
36. Install A/C compressor (Refer to section air conditioner system).
37. Install power steering hoses (Refer to section power steering system)
38. Raise an auto tension with spanner and then install drive belt.
39. Install air cleaner assembly.
40. Install flash air duct.
41. Connect negative battery cable.
42. Fill transaxle with ATF (Refer to auto transaxle fluid)
43. Adjust auto transaxle control cable.
44. Fill engine coolant with specified type and amount (Refer to section cooling system)
45. Fill power steering fluid (Refer to section power steering system).
46. Adjust accelerator cable (Refer to section intake and exhaust system).
47. Start engine and then check for leaks.
 Engine Mechanical System

Engine Mechanical System

Cylinder Block - Piston and Connecting Rod

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
1. Before removing connect rod, measure connecting rod side clearance.

side clearance : 0.0055~0.0133in (0.14~0.34mm)

2. Remove connecting rod cap.

3. Measure connecting rod bearing oil clearance.
(1) Remove all foreign material and oil from journals and bearing surface.
(2) Position Plastigage atop journals on axial direction.
(3) Install connecting rod cap and tighten.

Tightening torque : Pretighten 13.0~15.9lb-ft (17.6~21.6N·m, 1.8~2.2kg-m) and then tighten 40~50°.

(4) Loosen connecting rod cap bolts.

(5) Measure oil clearance at each journal.

Oil clearance : 0.00086~0.00157in (0.022~0.040mm)

Pin journal bearing selection

1. Check connecting rod big-end bore code.

• Number stamped connecting rod cap is big-end bore size code.

• Each of six Connecting rods must be set by same weight code in one engine.
 Connecting rod-end bore diameter

Code Connecting rod big-end bore diameter

7 2.27050~2.27074in (57.671~57.677mm)
8 2.27027~2.27050in (57.665~57.671mm)
9 2.27003~2.27027in (57.659~57.665mm)

2. Check crankshaft pin journal size code.

Record pin journal size code letters on cranksjaft web.

Reading order is left to ringht as shown, with No. 1 pin journal size code shown first.

Crankshaft pin journal diameter

Code Crankshaft pin journal diameter

A 2.12790~2.12814in 54.049~54.055mm)
B 2.12767~2.12790in (54.043~54.049mm)
C 2.127~2.12767in (54.037~54.043mm)

3. Choose proper pin journal bearing in below table.

Pin journal selection table

Connecting rod big-end bore size code

7 8 9
Crankshaft pin A Brown Green Yellow
 B Black Brown Green
journal size code
C Blue Black Brown

Pin journal bearing clearance : 0.000866~0.001574in (0.022~0.040mm)

Pin journal bearing thickness

Color Pin journal bearing thickness

Blue 0.07086~0.07098in (1.800~1.803mm)
Black 0.07074~0.07086in (1.797~1.800mm)
Brown 0.07062~0.07074in (1.794~1.797mm)
Green 0.07051~0.07062in (1.791~1.794mm)
Yellow 0.07039~0.07051in (1.788~1.791mm)

4. Position properly upper bearing and lower bearing to connecting rod and connecting rod cap and then install
connecting rod and connecting rod cap to crankshaft pin journal

Tightening torque :
Prehtening torque 13.0~15.9lb-ft (17.6~21.6N·m, 1.8~2.2kg-m) and then tight 40~50°.

INSPECTION
1. Inspect outer circumference of all pistons for crack scoring or unusual patterns. Replace piston piston if
necessary.

2. Check outside diameter of each piston at a 90° right angle tp piston pin, 0.4870in (12.37mm) below oil ring
land's lower edge.

Piston outside diameter

A type : 3.14822~3.14881in (79.965~79.980mm)
B type : 3.14885~3.14940in (79.981~79.995mm)
3. Insert piston ring into cylinder liner by hand and push it to 0.7874in (20mm) from bottom of ring travel in
using piston.

4. Measure each piston ring end gap with a feeler gauge. Replace if necessary.

End gap : 0.000787~0.001968in (0.02~0.05mm)

Cylinder liner
1. Inspect cylinder liner for scoring and sticking.
Replace cylinder liner if necessary.
2. Check cylinder liner inner diameter as shown in figure.

Cylinder liner inner diameter

A type : 3.14960~3.15019in (80.000~80.015mm)
B type : 3.15022~3.15078in (80.016~80.030mm)
 Engine Mechanical System

Engine Mechanical System

Cylinder Block - Crankshaft

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
Bearing ladder
1. Before removing bearing ladder, measure crankshaft end play.

End play : 0.0039~0.0118in (0.1~0.3mm)

2. Remove bearing ladder.

3. Measure main bearing oil clearance.
(1) Remove all foreign material and oil from journal and bearing surface.
(2) Position Plastigage atop journals in axial direction.
(3) Install bearing ladder and tighten in order shown in figure.

Tightening torque :
Tighten 7.2lb-ft (9.8N·m, 1.0kg-m), tighten 14.4lb-ft (19.6N·m, 2.0kg-m) and then tighten 90°.

(4) Loosen bearing ladder bolts in reverse order of tightening.

(5) Measure oil clearance at each journal.

Oil clearance : 0.00071~0.00153in (0.018~0.039mm)

Main journal bearing selection

1. Check cylinder block main bearing bore size code

Record cylinder block main bearing size code letters on front face of cylinder block as shown.
Read order is formleft to right with front main bearing bore code fire.
 Cylinder block main bearing bore diameter

Code Cylinder block main bearing bore diameter

A 2.81861~2.81889in (71.593~71.600mm)
B 2.81834~2.81861in (71.586~71.593mm)
C 2.81806~2.81834in (71.579~71.586mm)

2. Check crankshaft main journal size code.

Record pin journal size code numbers on crankshaft web.

Reading order is from left to left to right as shown, with No. 1 main journal size code shown first.

Crankshaft main journal diameter

Code Crankshaft pin journal diameter

1 2.66704~2.66727in (67.743~67.749mm)
2 2.66680~2.66704in (67.737~67.743mm)
3 2.66652~2.66680in (67.731~67.737mm)

3. Choose proper main journal bearing in below table.

Main journal bearing selection table

Cylinder block bearing bore size code

A B C
1 Brown Green Yellow
Cankshaft main journal size
2 Black Brown Green
code
3 Blue Black Brown

Main journal bearing clearance : 0.000708~0.001535in (0.018~0.039mm)

Main journal bearing thickness

 Color Pin journal bearing thickness
Blue 0.07586~0.07598in (1.927~1.930mm)
Black 0.07574~0.07586in (1.924~1.927mm)
Brown 0.07562~0.07574in (1.921~1.924mm)
Green 0.07551~0.07562in (1.918~1.921mm)
Yellow 0.07539~0.07551in (1.915~1.918mm)

4. Position properly upper bearing and lower bearing to cylinder block bearing ladder.
5. Set crankshaft to cylinder block and then install bearing ladder to cylinder block.

Tightening torque :
Tighten 7.2lb-ft (9.8N·m, 1.0kg-m), tighten 14.4lb-ft (19.6N·m, 2.0kg-m) and then tighten 90°.
 Engine Mechanical System

Engine Mechanical System

Cylinder Block - Cylinder Block

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENTS
 2000 > 2.5L GASOLIN(K5) >

DISASSEMBLY
1. Hold drive plate(ATX) with SST (OK590 111 001).

2. Remove drive plate lock bolt.

3. Remove backing plate, drive plate and adapter.
4. Remove SST (OK590 111 001).
5. Remove rear oil seal with 5 bolts.
6. Remove oil pan mounting bolts. (10EA)
Note position of 4 long bolts.

7. Remove oil pan with a scewdriver or suitable tool.

• Do not force tools between cylinder block and oil pan as this may damage sealing surface.
• Do not damage sealing surface when removing old sealant.

8. Remove oil filter element.

9. Disconnect oil pressure switch connector and oil temperture connector.
10. Remove timing belt pulley.
11. Remove oil pump and gasket with 14bolts.

12. Using a screwdriver covered by a rag, remove oil seal from pump cover side.
13. Remove oil strainer and discard "O" ring.

DISASSEMBLY
1. Hold drove plate(ATX) with SST (OK590 111 001).

2. Remove drive plate lock bolts.

3. Remove backing plate, drive and adapter.
4. Remove SST (OK590 111 001).
5. Remove rear oil seal with 5 bolts.
6. Remove oil pan mounting bolts(10EA).
Note position of 4 long bolts.

7. Remove oil pan with a screwdriver or suitable tool.

• Do not force tools between cylinder block and oil pan as this may damage sealing surface.
• Do not damage sealing surface when removing old sealant.

8. Remove oil filter element.

9. Disconnect oil pressure switch connector and oil temperature sensor connector.
10. Remove timing belt pulley.
11. Remove oil pump and gasket with 14 bolts.

12. Using a screwdriver covered by a rag, remove oil seal from pump cover side.
13. Remove oil strainer and discard "O" ring.
14. Remove lower crank case with 8 bolts.
15. Remove bearing ladder with 16bolts.

16. Remove main bearing and 2 thrust bearing halves from bearing ladder, keep in fitted order.
17. Use a numbering stamp and mark connecting rod cap and connecting rod with their corresponding cylinder
number.

Mark all rods on same side and mark a reference mark on block so that rods are installed in correct
position and direction. Failure to install rods properly with result in oil starvation, spun bearings, or
damaged internal engine components..

18. Remove 4 dowel bolts and remove connecting rod cap from No. 1 and No.2 connecting rods.
19. Release connecting rods from crankshaft.
20. Remove connecting rod bearing from connection rod and cap.
21. Turn crankshaft, remove bolts from remaining connecting rod caps and remove connecting rod bearing.
22. Remove crankshaft, remove main bearing and thrust bearing from cylinder block.
23. Position cylinder block to enable each piston and liner to be removed.
24. Carefully push each piston assembly and cylinder liner from cylinder block.
25. Remove piston assemblies from liners, keep liners in their respective positions.
26. Refit caps onto connecting rods, lightly tighten dowel bolts.
27. Hold piston upright and gently move connecting rod.
28. Release connecting rod and observe its movement.

Do not swing connecting rod wildly. Constant, hard contact with piston will cause a bell-mouth
condition that will require piston replacement.
29. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and
deformation.
30. Install SST as shown if figure.

31. Disassemble piston pin by press.

32. Remove water pump assembly and gasket with 7 bolts.

33. Remove timing belt auto-tensioner pulley.

34. Remove timing belt idler pulley.
35. Remove thermostat housing assembly and discard 'O' rings.

RESSEMBLY
1. Clean all parts before assembly.
2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
3. Replace main bearings and connecting rod bearing if they are peeling, burned or otherwise damaged.

Do not reuse old gasket or seals.

4. Install 'O' rings and thermostat housing assembly.

5. Install timing belt idler pulley.

Tightening torque : 39.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-,)

6. Install timing belt auto-tensioner pulley.

Tightening torque : 29.7~36.9lb-ft (40~50N·m, 4.1~5.1kg-m)

7. Install gasket and water pump assembly.

Tightening torque : 5~7.2lb-ft (6.8~9.8N·m, 0.7~1kg-m)

8. Install SST (OK993 110 A03/OK993 110 A02) to piston pin.

9. Apply a coat of engine oil to circumference of each piston pin and to small end of each connecting rod.
10. Reassemble piston and connectomg rod with aligning assembly mark.

11. Set piston and connecting rod on SST (OK993 110 A03) as shown in figure.

12. Insert pistion by press.

13. Check oscillation torque as shown as shown in figure.
If large end dose not drop by its own weight, disassemble piston pin and repeat step 8 to step 12.
14. Install three-piece oil ring on pistons.
(1) Apply engine oil to oil ring spacer and rails.
(2) Install oil ring spacer so that openinf faces upward.
(3) Install upper rail and lower rail.

• Upper engine oil to ring spacer and rails.

• Each rail can be installed with either face upward.

15. Check that both rails are expanded by spacer tangs as shown in figure by checking that both rails turn
smoothly in both directions.

16. Install second ring to piston first, then install top ring. Use piston ring expander.

Rings must be installed with "Y" marks facing upward.

17. Apply a liberal amount of clean engine oil to second and top piston rings.
18. Pistion opening of each ring as shown in figure.

19. Install piston assemblies to cylinder liners.

20. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes, and main bearing
journals thoroughly and dry components with compressed air.
21. Install grooved main bearing into saddles on cylinder block.
(Refer to main journal bearing selection.)
22. Install main bearings to bearing ladder.
23. Apply grease to crankshaft thrust bearings and install to bearing ladder with oil grooves facing outwards.
24. Set crankshaft on cylinder block.
25. Apply 2.0mm thick continuous bead of Hylomar Universal Blue sealatn around shoulder of cylinder liner.

Ensure that sealing faces of cylinder block and liners are clean.

26. Install bearing into connecting rod and cap.

(Refer to pin journal bearing selection)
27. Keeping cylinder liner 'square' to cylinder block, push each liner fully down until shoulder of liner seats
against cylinder block with 'front' mark on piston to engine front.
28. Install connecting rod caps, aligning marks made previous to disassembly and to specification.

Tightening torque :
Pretighten 13.0~15.9lb-ft (17.6~21.6N·m, 1.8~2.2kg-m) and then tighten 40~50°

When installing connecting rods, match marks made on connecting rod and cap to reference mark
made on cylinder block to prevent oil starvation to connecting rod bearing.

29. Install bearing ladder to cylinder block.

Tightening torque :
tighten 7.2lb-ft (9.8N·m, 1.0kg-m), tighten 14.4lb-ft (19.6N·m, 2.0kg-m) and then tighten 90°
30. Using plastic scraper, clean sealing surface on crankcase and cylinder block.
31. Apply a continuous bead of sealant to baths shown on crankcase then spread to an even film with brush or
roller.

To avoid contamination, assembly should be completed immediately after application of sealant.

32. Install lower crankcase to cylinder block.

Tightening torque : 15.9~20.9lb-ft (21.6~28.4N·m, 2.2~2.9kg-m)

33. Install 'O' ring and oil strainer.

Tightening torque : 5~7.2lb-ft (6.9~9.8N·m, 0.7~1kg-m)

34. Apply clean engine oil to new front oil seal and oil pump body.
35. Install front oil seal by hand.
36. Press oil seal into oil pump body.

Oil seal must be pressed in until it is nearly flush with front surface of oil pump body.
37. Install gasket and pump with 14 bolts.

Tightening torque : 5~7.2lb-ft (6.9~9.8N·m, 0.7~1kg-m)

38. Install timing belt pulley.

39. Reconnect oil pressure switch connector and oil temperature sensor connector.
40. Apply a small amount of engine oil to rubber seal of oil filter.
41. Install oil filter until rubber seal contacts base and then tighten filter wrench.

Tightening torque : 10~13lb-ft (13.7~17.6N·m, 1.4~1.8kg-m)

42. Clean crankcase and oil pan surfaces.

43. Apply continuous thin beads of sealant to paths on oil pan as shown then spread to an even film using a
brush or roller.

Sealant type : HYLOGRIP 2000

Bead width : 0.118in (3mm)

44. Install oil pan and tighten bolts in order shown in figure.
45. Lubricate rear oil seal running surface with engine oil.
46. Install rear oil seal and tighten.

Tightening torque : 5~7.2lb-ft (6.8~9.8N·m, 0.7~1kg-m)

47. Install backing plate, drive plate and adapter.

48. Install drive plate lock bolts and finger tight.
49. Hold drive plate(ATX) with SST (OK590 111 001).

50. Tighten drive plate lock bolts.

Tighten torque : 70~77lb-ft (95~105N·m, 9.7~10.7kg-m)

 Engine Mechanical System

Engine Mechanical System

Cooling System - Coolant

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION

• NEVER REMOVE REDIATOR CAP WHILE ENGINE IS HOT.

• WRAP A THICK CLOTH AROUND RADIATOR CAP BEFORE REMOVING.
• WHEN REMOVING RADIATOR CAP, LOOSEN SLOWLY TO FIRST STOP AND WAIT UNTIL
PRESSURE IN RADIATOR IS RELEASED, THEN COMPLETELY REMOVE.

Level
1. Verify that the coolant level is near the radiator filler neck.
2. Check that the level in the coolant reservoir is between the “Full” and “Low” marks.

3. Add coolant if necessary.

Coolant quality
1. Verify that there is no build up of rust or scale around the radiator cap of radiator filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.

Leakage
1. Connect a coolant system pressure tester to the radiator filler neck.
2. Apply 15 psi (103 kPa, 1.05 kg/cm) pressure to the system.
3. Verify that the pressure remains steady at 15 psi (130 kPa, 1.05 kg/cm).
4. If not, check system for coolant leakage.

REPLACEMENT

Never use 100% of water as coolant. The 45% mixfure of water and antifreeze is recommended. (To avoid
corrosion of cylinder head and cylinder block made of aluminum) - KV6 GASOLINE.

1. Remove radiator cap and loosen drain plug.

2. Drain coolant into a suitable container.
3. Flush cooling system with water until all traces of color are gone ; then let system drain completely.
4. Install drain plug.
5. Fill with proper mixture of ethylene glycol-based coolant.

Coolant capacity : 9.93 Us qt (9.4 liter, 8.27 lmp qt)

6. Run the engine with the radiator cap removed until the upper radiator hose is hot.
7. With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
8. Install the radiator cap.
9. Allow engine to cool and coolant level.
 Engine Mechanical System

Engine Mechanical System

Cooling System - Water Pump

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

REMOVAL
Water pump
1. Drain engine coolant.

2. Remove front timing belt.

3. Remove water pump assembly and gasket with 7 bolts.

INSTALLATION
1. Install new gasket and water pump assembly.

Tightening torque : 5~7.2 lb-ft (6.8~9.8 N·m, 0.7~1 kg-m)

2. Install No.3 engine mounting bracket.

3. Refill engine coolant.
 Engine Mechanical System

Engine Mechanical System

Cooling System - Thermostat

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Disconnect negative battery cable.
2. Drain engine coolant.
3. Remove accelerator cable.

4. Disconnect TPS and IAC valve connectors.

5. Disconnect breather hose from throttle body.
6. Remove high-tension cords.
7. Disconnect breather hoses from LH camshaft cover

8. Disconnect breather hose and fuel return hose at surge tank.

9. Remove harness coupler bracket from surge tank.

10. Disconnect VICS valve connector, brake vacuum hose and purge control vacuum hose.
11. Remove surge tank with four bolts and two nuts.
12. Disconnect ignition coil connector, fuel injector connector and intake air-temperature sensor connector.

13. Disconnect fuel hose from injector rail.

KEEP OPEN FRAMES AND SPARKS AWAY FROM OPEN FUEL LINES, OR A FIRE OR
EXPLOSION MAY RESULT.

14. Disconnect coolant hose from intake manifold.

15. Remove intake manifold with 5 bolts and 2 nuts.
16. Disconnect coolant hoses from thermostat.
17. Remove thermostat housing assembly.

If thermostat is damaged, have to replace assembly.

 INSTALLATION
1. Install new “O” ring and thermostat housing assembly.

Tightening torque : 10.9~14.5 lb-ft (14.7~19.6 N·m, 1.5~2.0 kg-m)

2. Reconnect coolant hoses to thermostat housing.

3. Install intake manifold.
4. Reconnect coolant hose to intake manifold.
5. Reconnect fuel hose to injector rail.
6. Reconnect ignition coil connector, fuel injector connector and intake air-temperature sensor connector.

7. Install surge tank.

8. Reconnect VICS valve connector, brake vacuum hose and purge control vacuum hose.

9. Install harness coupler bracket from surge tank.

10. Reconnect breather hose and fuel return hose to surge tank.
11. Reconnect breather hoses to LH camshaft cover.
12. Install high-tension cords.
13. Reconnect breather hose to throttle body.
14. Reconnect TPS and IAC valve connectors.
15. Install accelerator cable.
16. Measure free play of accelerator cable.

Free play : 0.04~0.11 in (1~3 mm)

17. Refill engine coolant.
18. Reconnect negative battery cable.
 Engine Mechanical System

Engine Mechanical System

Cooling System - Radiator

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Drain engine coolant.

2. Remove cooling fan assembly.

3. Disconnect coolant upper hose.
4. Disconnect reserve tank hose.
5. Disconnect coolant lower hose.
6. Remove radiator brackets.

7. Remove radiator.

INSTALLATION
1. Install radiator.
2. Install radiator bracket.
3. Reconnect coolant lower hose.
4. Reconnect reserve tank hose.
5. Reconnect coolant upper hose.
6. Install cooling fan assembly.
7. Refill engine coolant.
 Engine Mechanical System

Engine Mechanical System

Cooling System - Radiator Cap

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
Radiator cap valve
1. Remove foreign material from radiator cap valve and the valve seat.
2. Attach radiator cap to radiator cap tester. Apply pressure gradually to 15 psi (103 kPa, 1.05 kg/cm²)

3. Wait about 10 seconds. Verify that pressure has not decreased.

4. Replace radiator cap as necessary.

Negative pressure valve

1. Pull negative pressure valve to open it. Verify that it closes completely when released.
2. Check for damage on contact surfaces, and for a cracked of deformed seal.
3. Replace radiator cap as necessary.
 Engine Mechanical System

Engine Mechanical System

Cooling System - Cooling Fan Motor Assembly

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COOLING FAN
 2000 > 2.5L GASOLIN(K5) >

INSPECTION

Cooling fan motor relay is located the engine compartment fuse/relay box.

1. Disconnect negative battery cable.

2. Remove cooling fan motor relay from engine compartment fuse/relay box.
3. Check continuity with an ohmmeter.

Terminal Continuity
3-4 No
1-2 Yes

4. Apply 12V to terminal 1 and ground to terminal 2.

Check for continuity between terminals 3 and 4
5. If there is no continuity, replace fan motor relay.

Engine coolant temperature

1. Check for resistance.

Water temperature Resistance

-4°(-20°C) 14.6~17.8kΩ
68°(20°C) 2.2~2.7kΩ
176°(80°C) 0.29~0.35kΩ

2. If not as specified, replace the engine coolant temperature sensor.

REMOVAL
1. Disconnect negative battery cable.
2. Remove fresh air duct.
3. Disconnect cooling fan motor connector.
4. Remove two bolts securing coolant upper hose.

5. Remove three bolts securing cooling fan assembly.

6. Remove cooling fan assembly.

7. Remove U-clip securing cooling fan and remove cooling fan.
8. Remove nuts securing fan motor and remove fan motor.

INSTALLATION
1. Install fan motor.
2. Install cooling fan to fan motor by use of U-clip.
3. Install cooling fan assembly.
4. Reconnect cooling fan motor connector.
5. Install two bolts securing coolant upper hose.
6. Install fresh air duct.
7. Reconnect negative battery cable.
 Engine Mechanical System

Engine Mechanical System

Lubrication System

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

REPLACEMENT

BE CAREFUL WHEN DRAINING BECAUSE OIL IS HOT AND COULD CAUSE PERSONAL INJURY.

1. Warm engine to normal operating temperature and turn engine off. Position a suitable container under oil
pan.
2. Remove oil filler cap and oil pan drain plug.
3. Allow oil to be fully drained.
4. Install drain plug with new gasket.

Tightening torque : KV6 Gasoline : 18.1~21.7 lb-ft (24.56~29.4 N·m, 2.5~3.0 kg-cm)
J3 TCI Diesel : 23.1~30.4 lb-ft (31.4~41.2 N·m, 3.2~4.2 kg-m)

5. Refill engine with specified type and amount of engine oil.

6. Install oil filler cap.
7. Run engine and check for leaks.
8. Check oil level by level gauge and add oil if necessary.

Oil pressure check

1. Disconnect and remove oil pressure switch.
2. Install oil pressure gauge into oil pressure switch installation hole.
3. Warm engine to normal operating temperature.
4. Run engine and note gauge readings.

Oil pressure :
KV6 Gasoline :
49.8 psi (343 kPa, 3.5 kg/cm) - Idle rpm
49.8~71.1 psi (343~490 kPa, 3.5~5.0 kg/cm) - 3,000 rpm
J3 TCI Diesel : 45.5~71.1 psi (314~490 kPa, 3.2~5.0 kg/cm) - 3,000 rpm

5. If pressure is not within specification, check for cause, and repair.

6. Remove oil pressure gauge and install oil pressure switch.

Tightening torque : 8.7~13.0 lb-ft (11.7~17.6 N·m, 1.2~1.8 kg-m)

Oil filter replacement

1. Remove oil filter with oil filter wrench. If rubber seal is stuck to engine, remove it.
2. Apply a small amount of clean engine oil to rubber seal of new filter.
3. Install oil filter and turn it by hand until rubber seal contacts base.
4. Tighten filter 1-1/6 turns with filter wrench.

Tightening torque :
KV6 Gasoline : 10~13 lb-ft (13.7~17.6 N·m, 1.4~1.8 kg-m)
J3 TCI Diesel : 13~16 lb-ft (17.6~21.6 N·m, 1.8~2.2 kg-m)
5. Start engine and check for leaks.
6. Turn engine off, and wait 5 minutes. Check oil level and add oil if necessary.
 Engine Mechanical System

Engine Mechanical System

Lubrication System - Oil Pan

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Disconnect negative battery cable.
2. Drain engine oil to suitable container.
3. Remove exhaust manifold.
4. Remove oil pan mounting bolts.
5. Remove oil pan.

INSTALLATION

• If oil pan is reused, remove ail foreign material from sealing surfaces of cylinder block and oil pan
• If bolts are reused, remove old sealant from bolt threads.

1. Apply a continuous bead of silicone sealant to oil pan along inside of bolt holes on contact surfaces.

The oil pan must be installed no longer than 5 minutes after silicone sealant is applied.

2. Tighten oil pan mounting bolts.

Tightening torque : 15.9~19.5 lb-ft (21.6~26.5 N·m, 2.2~2.7 kg-m)

3. Install exhaust manifold.

4. Fill with specified amount and type of engine oil.
5. Connect negative battery cable.
6. Start engine and check for leaks.
7. Check oil level and add oil if necessary.
 Engine Mechanical System

Engine Mechanical System

Lubrication System - Oil Pump

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENT
 2000 > 2.5L GASOLIN(K5) >

REMOVAL
1. Remove front timing belt.
2. Remove oil pump and gasket with 14 bolts.

3. Using a screwdriver covered by a rag, remove front oil seal from pump cover side.

INSTALLATION
1. Apply clean engine oil to new front oil seal and oil pump body.
2. Install front oil seal by hand.
3. Press oil seal into oil pump body.

Oil seal must be pressed in until it is nearly flush with front surface of oil pump body.

4. Install new gasket and oil pump with 14 bolts.

Tightening torque : 5~7.2 lb-ft (6.9~9.8 N·m, 0.7~1 kg-m)

5. Install No. 3 engine mounting bracket.

 Engine Mechanical System

Engine Mechanical System

Intake And Exhaust System

Model : Carnival / Sedona

 2000 > 2.5L GASOLIN(K5) >

INSPECTION
Accelerator cable
1. Depress accelerator pedal to floor and check that the throttle valve is fully opened.
Adjust with bolt A, if necessary.

2. Measure free play of the accelerator cable.

Free play : 0.04~0.11 in (1~3 mm)

3. If not as specified, adjust by turning locknut A.

 Engine Mechanical System

Engine Mechanical System

Intake And Exhaust System - Air Cleaner

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENT
 2000 > 2.5L GASOLIN(K5) >

INSPECTION
Check the air cleaner element for excessive dirt damage, or oil and replace or clean if necessary.

Use a compressed air to clean to element from the internal side to the exhaust side, or from the upper to
the lower.
 Engine Mechanical System

Engine Mechanical System

Intake And Exhaust System - Front Exhaust Pipe

Model : Carnival / Sedona

2000 > 2.5L GASOLIN(K5) >

COMPONENT