2007 KIA CARNIVAL ECU

a.When pressing the rod, use a vertical vice certainly.
b. There is a high possibility for air to get in the high pressure chamber, when using a horizotal vice.
c. Do not apply more load than 400N on the rod.
d. Do not press the rod until its position is below 2.5mm from the body surface.
e. The projection of the rod is secured more than 2.5mm.
a.Repairing orders when disassembling the auto tensioner and reassembling it to the engine, or pulling
the pin out before its installation ;
a. Stand it vertically for about five minutes.
b. Press the rod with the force, 150~200N.
c. If the rod has a stiffness, press it slowly and insert the pin into the set hole.
d. If not(the tensioner is in 'sponge' state), press the rod slowly from its maximum projection to 2.9mm
position(the meeting point with the rod and the hole of the body) two or three times.
Afterwards, if stiffness is sensed, insert the pin into the hole. However, if not, scrap the tensioner.
(2) Install the auto tensioner(A) to the front case with the set- pin inserted.
Tightening torque
19.6 ~ 26.5Nm(2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb- ft)
4.Ensure the timing marks on the camshaft and the crankshaft sprockets.
5.Install the timing belt.
Crankshaft sprocket(A) → Idler(B) → Bank 2 exhaust camsprocket(C) → Water pump pulley(D) → Bank 1 exhaust
camsprocket(E) → Tensioner pulley(F).

The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of
the radiator support upper member assembly.
18.Drain engine oil.
19. Remove the brake caliper.(Refer to DS group).
20. Disconnect the air conditioning compressor hoses.(Refer to HA group).
21. Remove the front wheels and tires.(Refer to DS group).
22. Remove the brake caliper hub nut.(Refer to DS group).
23. Remove the tie rod end ball joint from the knuckle.(Refer to DS group)
24. Remove the driver shaft and the stabilizer bar link(Refer to SS group).
25. Remove the front muffler(A).
26.Using a floor jack, support the engine and transaxle assembly.
After removing the sub frame mounting bolt , the engine and transaxle assembly may fall downward, and so
support them securely with floor jack.

support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
27. Remove the engine mounting bracket(A) and the ground(B).
28.Remove the transaxle insulator mounting bolt(A).
Remove the ECM(Electronic Controlled Mounting) nuts and the solenoid valve connector for A/T vehicles.
29. Supporting the engine and transaxle assembly with a jack, remove the assembly from the vehicle by loosening the
sub frame mounting bolts and lifting up the vehicle slowly.
When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body
components.
Front
Real

M8 : 15.7Nm(1.6 kgf.m, 11.6lb- ft) + 90°
M10 : 29.4Nm(3.0 kgf.m, 21.7lb- ft)+ 90°
a.Use new main bearing cap bolt with engine oil applied.
b. If any of the bearing cap bolts are broken or deformed, replace it.
c. Washers have their direction(Up/Down)
d. Assemble the bearing cap bridge on which its arrow mark faces the engine front.
e. Before tightening, make the bearing caps be seated on the block firmly.
Use SST( 09221 - 4A000 ), install main bearing cap bolts.
(2) Check that the crankshaft turns smoothly.
10. Check crankshaft end play.
11. Install the piston and connecting rod assemblies.
a.Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores.
b. When installing the piston, ensure that the coat on the cylinder wall is not damaged or scratched.
(1) Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder,
and tap it in using the wooden handle of a hammer.
(2) Stop inserting the piston when the ring inserted in the cylinder and check the alignment of the journal and the
connecting rod.
(3) Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts.
Tightening torque

THERMOSTAT
1.Immerse the thermostat in water and gradually heat water.
2.Check the valve opening temperature.
Valve opening temperature : 82°C (177°F)
Full opening temperature : 95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : Min. 10mm (0.4in.) at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
ENGINE COOLANT REFILLING AND BLEEDING
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high
pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or
the paint. If any coolant spills, rinse it off immediately.
1. Make sure the engine and radiator are cool to the touch.
2. Open the radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and clean the reservoir tank.
6. Fill water slowly through the radiator cap. Push the upper/lower hoses of the radiator so as to bleed air easily.
7. Warm the engine until the cooling fan operates 2~3 times.
Accelerate the engine 2~3 times without load.
8. Wait until the engine is cold.
9. Repeat the steps 1~8 until the water drained is clean.
10. Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the
radiator so as to bleed air easily.
11. Start the engine and run so coolant circulates.
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
12. Repeat 11 until the cooling fan cycles 3 ~ 5 times and bleed air sufficiently out of the cooling system.

2007 > 2.7L V6 GASOLINE >
THE MICRO 570 ANALYZER
The MICRO 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter
and generator.
Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when
working with batteries.
KEYPAD
The MICRO570 button on the key pad provides the following functions :
BATTERY TEST PROCEDURE
1.Connect the tester to the battery.
a. Red clamp to battery positive (+) terminal.
b. Black clamp to battery negative ( - ) terminal.
Connect clamps securely. If "CHECK CONNECTION" message is displayed on the screen, reconnect clamps
securely.

1.Turn the ignition switch to "OFF".
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B"
terminal of alternator and the ( - ) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the "B" terminal of alternator and the ( - ) lead wire of voltmeter to the (+) terminal of battery.
TEST
1.Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.
RESULT
1.The voltmeter may indicate the standard value.
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color
change due to an over - heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.
OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION
1.Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section "Battery".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the section "Inspect
drive belt".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure
to connect the ( - ) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and ( - ) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

8.Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed
cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the
posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after tightening.
When batteries are being charged, an explosive gas forms beneath the cover of each cell. Do not smoke
near batteries being charged or which have recently been charged. Do not break live circuit at the terminals
of batteries being charged.
A spark will occur when the circuit is broken. Keep open flames away form battery.