2007 KIA CARNIVAL service

b.Be sure to install the harness wires so that they are not pinched, or interfere with other parts.
c.Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal- to- metal
contact. Poor grounding can cause intermittent problems that are difficult to diagnose.
Precautions for Electrical Inspections
a.When using electrical test equipment, insert the probe of the tester into the wire side of the connector.
Do not insert the probe of the tester into the terminal side of the connector, and do not tamper with the connector.
b.Use a u - shaped probe. Do not insert the probe forcibly.
c. Use specificed service connectors for troubleshooting.

2007 > 2.7L V6 GASOLINE >
SPECIAL SERVICE TOOLS
Tool(Number and Name) IllustrationUse
Deployment tool
0957A- 34100A
Airbag deployment tool
Deployment adapter
0957A- 3F100
Use with deployment tool.
(PAB, SAB)
Deployment adapter
0957A- 38500
Use with deployment tool.
(DAB, PAB, CAB, BPT)
Dummy
0957A- 38200
Simulator to check the resistance of
each wiring harness
Dummy adapter
0957A- 3F000
Use with dummy
(PAB, SAB)
Dummy adapter
0957A- 1C000
Use with dummy
(DAB, CAB, BPT)
DAB : Driver Airbag
PAB : Passenger Airbag
SAB : Side Airbag
CAB : Curtain Airbag
BPT : Belt Pretensioner

DEPLOYING THE AIRBAG OUT OF THE VEHICLE
If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damage during transit,
storage or service, it should be deployed as follows :1. Position the airbag face up, outdoors on flat ground at least thirty feet (10meters) from any obstacles or people.
DISPOSAL OF DAMAGED AIRBAG
1.If installed in a vehicle, follow the removal procedure of driver's airbag front passenger's and side airbag.
2. In all cases, make a short circuit by twisting together the two airbag inflator wires.
3. Package the airbag in exactly the same packing that the new replacement part come in.

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Item Specification
Master cylinder
· Type
· I.D. mm(in)
· Piston stroke mm(in)
· Fluid level warning sensor Tandem type
26.99/(1.063)
30(1.18)
Provided
Brake booster
· Type
· Boosting ratio 8 + 9 in Tandem
9.0 : 1
Front brake(Disc)
· Type
· Disc O.D.
· Disc thickness
· Pad thickness
· Cylinder type
· Cylinder I.D. Floating type with ventilated disc
298 mm (11.73 in)
28 mm (1.10 in)
10.5 mm (0.41 in)
Double piston
Ø48 mm (Ø1.89 in)
Rear brake(Disc)
· Type
· Disc O.D.
· Disc thickness
· Pad thickness
· Cylinder type
· Cylinder I.D Floating type with solid disc
302 mm (11.89 in)
12 mm (0.47 in)
10 mm (0.39 in)
Single piston
Ø42.9 mm (Ø1.69 in)
Parking brake
· Type
· Actuation
· Drum DIH(Drum in hat)
Foot brake
Ø190 mm (Ø7.48 in)
O.D=Outer Diameter
I.D=Inner Diameter
ABS : Anti- lock Brake System
ESP : Electronic Stability Program
SERVICE STANDARD
Items Standard value
Brake pedal height 192.4 mm(7.57 in)
Brake pedal full stroke 122 mm (4.8 in)
Adjust Brake pedal full stroke 60 mm (2.36 in)
Brake pedal free play 3 ~ 8 mm(0.11 ~ 0.31 in)
Stop lamp switch outer case to pedal stopper clearance 1.0 ~ 1.5 mm (0.04 ~ 0.06 in)
Booster push rod to master cylinder piston clearance 0.6 ~ 1.7(0.02 ~ 0.07 in)(at 500 mmHg)
Parking brake pedal stroke when pedal assembly is depressed with
294N (30kgf, 66lb force) 145 mm (5.71 in) above
Front disc brake pad thickness 10.5 mm (0.41 in)
Front disc thickness 28 mm (1.10 in)
Rear disc brake pad thickness 10 mm (0.39 in)
Rear disc brake disc thickness 12 mm (0.47 in)
Rear parking brake liner thickness 4 mm (0.16 in)

BRAKE SWITCH CLEARANCE
Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal arm)
then brake off the switch 3/4 turn to make 0.5 ~ 1.0 mm(0.0197 ~ 0.0394 in.) of clearance between the brake switch
connector. Make sure that the brake lights go off when the pedal is released.
PEDAL FREE PLAY
1.With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
Free play: 3 ~ 8 mm (0.12 ~ 0.31 in.)
2.If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it may
result in brake drag.
INSPECTION OF FRONT DISC BRAKE PAD
1.Check the brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.5 mm ( 0.41 in)
Service limit : 2 mm (0.0787 in)

a.If the pad thickness is out of specilfication, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD
1.Check the rear disc brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in)
Service limit : 2.0 mm (0.0787 in)
a.If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.

10.After installation, check for leaks at hose and line joints or connections, and retighten if necessary.
INSPECTION
FRONT BRAKE DISC THICKNESS CHECK
1. Remove all rust and contramination from the surface, and measure the disc thickness at 8 points, at least, of same
distance (5mm) front the brake disc outer circle.
Front brake disc thickness
Standard value : 28 mm(1.10 in)
Limit : 26 mm(1.02 in)
2. Thickness variation should not exceed 0.005mm (0.0002 in) (circumference) and 0.01 mm (0.0004 in)(radius) at
any directions.
3. If wear exceeds the limit, replace the discs and pad assemblies on the left and right sides of the vehicle.
FRONT BRAKE PAD CHECK
1.Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value : 11 mm (0.43 in)
Service limit : 2 mm (0.0787 in)
2.Check that grease is applied, to sliding contact points and the pad and backing metal for damage.
FRONT BRAKE DISC RUN OUT CHECK
1.Place a dial gauge about 5mm (0.2 in.) from the outer circumference of the brake disc, and measure the run out of
the disc.

REAR BRAKE PAD CHECK
1.Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value.
Pad thickness
Standard value :
10.0 mm ( 0.39 in)
Service limit : 2.0 mm (0.08 in)
2.Check that grease is applied, and the pad and backing metal for damage.
REAR BRAKE DISC RUN OUT CHECK
1.Place a dial gauge about 5 mm (0.2 in) from the outer circumference of the brake disc, and measure the run out of
the disc.
Brake disc run out
Limit : 0.05 mm (0.002 in) or less (new one)
2.If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out
again.