2007 KIA CARNIVAL Workshop Manual

3.The two coolant temperature sensors are installed to the heater inner. The sensor valves determine heater
operation.
4. One of the temperature sensors functions to prevent the heater from overheating.
If the sensor temperature valve exceeds 125°C, the fuel will be cut and the heater will be deactivated by the
determination of the overheating of the heater.
The other temperature sensor determines the operation mode of the fuel fired heater.The temperature of this
sensor enables to activate the heater at full load(5kw) or half load(2.5kw).
• The coolant temperature shown on the above Figure is the value of the inner sensor and the actual coolant
temperature is higher about 5°C ~7°C than the above value.
OPERATION
Switch on/ Operation start
The fuel fired heater is operated when the coolant temperature is below 68°C and the ambient temperature is below
2°C after starting the engine.
At this time, the glow plug and combustion air fan are operated first and after 30 seconds, the dosing pump is
operated with stopping the combustion fan for 3 seconds.
After that, the operation of the fan increases continuously until it approaches to full load within 56 seconds. If fuel
supply reaches to full load the glow plug does not operate and the operation of the fan reaches to full load.
After that the glow plug monitors ignition condition as a flame sensor for 45 seconds.
The above operation procedure is done automatically and in case the ignition fails, the above operation will be done
again automatically.
If the condition of ignition failure sustains continuously, fuel supply and fan operation will be stopped and error codes
will be stored to find cause of failure.
Generally, the cause of ignition failure during combustion is caused by the automatic re- operation of the above
procedure.
Operation for heating
The fuel fired heater operates at full load when the coolant temperature is below 68°C and the ambient temperature is
below 2°C after starting the engine.
It operates at half load when the coolant temperature is 74°C and it operates at idle mode when the coolant
temperature is 78°C.
The fuel fired heater during the transformation process does a cleaning function from the half mode to the idle mode.
At idle mode, all components do not work.
The fuel fired heater operating at idle mode turns into the half load when the coolant temperature is 74°C. At this time,
if the coolant temperature drops again below 68°C, the heater operates with full load and turns into the idle mode if
the temperature is 78°C.
This serial operating process is performed automatically.
Key switch off / Operation stop
The fuel fired heater ECU stops the operation of the fuel pump and cuts fuel supply when shutting off the engine
during the heater operation.
The heater conducts cleaning operation at this time.
This is a process of burning the fuel completely supplied in the heater inner.
In this process, the glow plug and combustion air fan are operated.

When the cleaning process is over, the operation of the heater is stopped.
The time for cleaning when the engine is turned off during the operation of the heater at full load is about 175
seconds.
About 100 seconds are required to conduct the cleaning of the heater at half load condition.
The operating sound of cleaning the heater is heard from the outside of the heater after turning the engine off and this
is a normal process of operation

2007 > 2.7L V6 GASOLINE >
INSPECTION
OPERATION TEST
Fuel-fired heater operation test by force using Hi-Scan
1. Start the engine.
2. Connect the Hi - Scan to the vehicle.
3. Select "SORENTO" and then select "FUEL FIRED HEATER".
4. Select "04. ACTUATION TEST" mode.
5. Select "PREFILLING + HEATING" to conduct the performance test after replacing the fuel fired heater system.
Fuel supply and heating will be initiated if the "F1 key STRT" is pressed.
However, a repair or replacement of the components related to the fuel line system in the fuel- fired heater were not
done, operate the component by force after selecting the appropriate item from the menu screen.
Do not operate the system by force with selecting the “ PREFILLING + HEATING ” option if no repair for the
fuel line relating components has been done.
This means the fuel is in the fuel line.If an excessive fuel is supplied, it may cause smoke and abnormal
"Banging" noise when the fuel is burned.
If the "F2 KEY STOP" is pressed, operation test is stopped.
For self - diagnosis test and sensors outputs during compulsory operation test, press "ESC KEY".
When a self - diagnosis test is completed, disconnect the self - diagnosis connector or press "F2 KEY STOP"
from the "PREFILLING + HEATING" menu to stop the compulsory operation.
In case of selecting the individual part (ex. Combustion air fan, water pump, ), press "ESC KEY" to stop the
test.
In case of selecting the "PREFILLING + HEATING" option, about 2 minutes are required to conduct cleaning
process after pressing the "F2 KEY STOP".
It is a normal process to burn the fuel left in the fuel line.
6. To conduct self diagnosis test, press "ESC" and then "01. DIAGNOSTIC TROUBLE CODES" option.
7.Select "02. CURRENT DATA" to view the current status of the components.

Component test
1.Using the Hi - Scan, conduct component test after selecting "FUEL FIRED HEATER" and "ACTUATION TEST"
mode.
2. After conducting component test, perform self - diagnosis test.
3. It is recommended to conduct the fuel fired heater system test after completing the component test.
4. Test values for glow plug.
Resistance : 0.324 W ~ 0.360 W
Current : < 5mA

2007 > 2.7L V6 GASOLINE >
TROUBLESHOOTING
SYMPTOM REMEDY
Fuel smell Check fuel system on vehicle.
Check the fuel supply line in the fuel fired heater for fuel leaking and
fuel hose for twisting or clogging.
If none of above is affected, there is likelihood of fuel leaking from the
heater inner. Repair the heater after removing it.
Heater does not work at full load Repair the heater after removing it.
White smoke occurs continuously during
operation Repair the heater after removing it.
Shortage of coolant
Smoke occurs during operation
Excessive exhaust gas smell Check coolant hose for leaking, twisting and hose clamp for looseness.
If above items are normal, leaks from the heater inner may cause these
symptoms.
Repair the heater after removing it.
Loss of fuel Check fuel system on vehicle.
Check the fuel supply line in the fuel fired heater for fuel leaking and
fuel hose for twisting or clogging.
If above items are normal, there is likelihood of fuel leaking from the
heater inner.
Repair the heater after removing it.

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
ITEM OPERATION STATESPECIFICATION
Fuel fired heater body Heater discharge
Full load
5.0kw
Half load 2.5kw
Full load Diesel
Fuel consumption Full load
0.63 l/h
Half load 0.32 l/h
Rated voltage y12.0V
Operation voltage range y9.5V~15.0V
Power consumption Full load
37w(Normal)
Half load 13w(Normal)
Permissible ambient temperature At operation
- 40°C~80°C
At storage - 40°C~120°C
Permissible operation pressure y
0.4bar ~ 2.5bar
Minimum coolant flow volume y
250 l/h
Permissible CO₂ value y 8~13 vol %
ITEM SPECIFICATION
Dosing pump Rated voltage
12.0V
Operation voltage range 9.0V ~ 15.0V
Maximum power consumption 4w(Normal)
ITEM SPECIFICATION
Ambient switch Rated voltage
12.0V
Temperature of ON/OFF ON : 2°C(Tolerance : + 3°C, - 2°C)
OFF : 8°C(Tolerance : + 2°C, - 3°C)

Positive Temperature Coefficient Heater

2007 > 2.7L V6 GASOLINE >
DESCRIPTION
PTC (Positive Temperature Coefficient) heater (A) is an electric heater using a PTC element as an auxiliary heating
device that supplements deficiency of interior heat source in highly effective diesel engine (U engine).
An electric heater heats up the interior by directly heating the air that passes through the heater.
PTC = positive Temperature Coefficient
The name itself implies that the element has a proportional resistance change sensitive to temperature. PTC heater is
installed at the exit or the backside of heater core.
OPERATION PRINCIPLE
ECM outputs a PTC on signal. Operate PTC from 1st setting to 3rd setting with an interval of 15 seconds.
Heat up the air, which passes through a heater core.
OPERATION CONDITION
Judge the condition by ambient temperature is below 5°C, coolant temperature is below 70°C, and battery voltage is
above 11V and engine RPM is above 700RPM.