2007 KIA CARNIVAL Workshop Manual

2007 > 2.7L V6 GASOLINE >
REMOVAL
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove air cleaner mounting bolts (B) from the air cleaner mounting bracket and air cleaner body (A).(LHD)
2.Remove the air cleaner assembly (A) by removing the air cleaner mounting bolt (B) from the bracket.(LHD)
3.Remove the surge tank.(Refer to EM Gr.)
(RHD- GSL 3.8)
4. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
[LHD]
[RHD]

5.Remove the brake fluid from the master cylinder reservoir (C) with a syringe.
6. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
7. Remove the master cylinder mounting nuts (B) and washers.
[LHD]
[RHD]
8.Remove the master cylinder(C) from the brake booster. Be careful not to bend or damage the brake lines when
removing the master cylinder.
INSTALLATION
1.Install the master cylinder on the brake booster with 2 nuts.
2. Connect the two brake tubes and the brake fluid level sensor connector.
[LHD]

[RHD]
3.Fill the brake reservoir with the brake fluid and bleed the brake system (Refer to 'Bleeding of brake system').
DISASSEMBLY
1.Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder, after remove mounting screw (A).
[LHD]
4.Remove the retainer ring (A) by using the snap ring pliers.

5.Remove the primary piston assembly (A).
6. Remove the pin (C) with the secondary piston (B) pushed completely using a screwdriver. Remove the secondary
piston assembly (B).
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1.Check the master cylinder bore for rust or scratching.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
a.If the cylinder bore is damaged, replace the master cylinder assembly.
b. Wash the contaminated parts in alcohol.
REASSEMBLY
1.Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver (A) and install the cylinder pin (B).

4.Install the retainer ring (A) after installing primary piston assembly.
5.Mount two grommets.
6. Install the reservoir on the cylinder.

Brake Line

2007 > 2.7L V6 GASOLINE >
COMPONENT

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the brake hose clip (A).
2.Loosen the brake tube (A) nut holding the brake hose (B) nut with a wrench.
3.Remove the brake hose (B).
4. Remove the brake hose connecting bolt (A) from the caliper assembly.
INSTALLATION
1.Install the brake hose (A) connecting bolt (B) and washer (C).