2007 KIA CARNIVAL brakes

2007 > 2.7L V6 GASOLINE >
Electronic Control System
DESCRIPTION
The electronic control system used in the new generation auto transaxle is far superior to the previous systems. This
system is able to adopt a variable shift pattern for smooth and problem free shifting.
A solenoid valve is applied to each of the clutches and brakes and is independently controlled. Feedback control and
correction control is performed in all gears as well as utilization of mutual control system to increase shift feeling.
The torque converter damper clutch uses a partial lock up and full lock - up system. An additional control method called
the HIVEC system (neural network) is adopted to increase shift feeling.
Block Diagram (CAN)
ELECTRIC CONTROL LOCATION
The TCM(PCM) is located on the intake manifold in the engine room.

2007 > 2.7L V6 GASOLINE >
Description
The automatic transmission is a combination of 3 - element 2 - phase 1 - stage torque converter and double shaft
electrocally - controlled unit which provides 4 speeds forward and 1 reverse. To improve the efficiency of power
transmission, the line pressure control was changed applying “Variable Force Solenoid (VFS) valve” on this model.
However, adopting VFS on this model, the line pressure is variably changed according to TPS and the vehicle speed,
this will enable more improved efficiency of power transmission and fuel consumption.
Characteristics
Some of the characteristics include:
▶Different power transfer
▶Different component layout
▶New shift logic(HIVEC) to improve shift feeling
▶Position of Valve Body
▶Variable shift pattern
▶Communication protocol and method
▶Step gate type shift lever.
Item Details
Weight Reduction 1. Aluminum oil pump
a. 2.3kg Approx
2. Pressed parts a. Retainer and hub of brakes and clutches
b. Carrier of planetary gear set
Better shift quality 1. Independent control of clutches and brakes enabled better control of
hydraulic pressure and skiped shifts (4 to 2, 3 to 1)
2. During N to D or N to R shift, feedback control adopted.
3. When starting from Creep condition, reduction of shock.(Creep condition is
controlled with 1st gear)
4. Solenoid valve frequency is increased for more accurate control. 35Hz to
61.3Hz except DCCSV that is 35Hz and VFS that is 600Hz.
5. HIVEC adoption for better shift feeling.
6. Variable shift pattern.
Increase in Power train efficiency 1. Fully Variable Line Pressure
2. VFS(Variable Force Solenoid)
- Manual shifting possible
- Step gate type shift lever

BRAKES
The gear changing mechanism utilizes two multi- disc brakes.
LOW&REVERSE BRAKE AND SECOND BRAKE
The low&reverse brake(A) operates in 1st and reverse gears, when the vehicle is parked, and during manual
operation. It locks the low&reverse annulus gear and overdrive planetary carrier to the case.
The second(C) brake(B) operates in 2nd and 4th gears and locks the reverse sun gear(D) to the case.
The components comprising the low&reverse brake and second brake are as illustrated below.
As shown, the discs and plates of the two brakes are arranged on either side of the rear cushion plate(E), which is
itself secured to the case(F) by a snap ring.
OWC
To improve the shift feeling from 1st to 2nd gear, OWC was adopted on the low&reverse brake annulus gear. Instead
of hydraulic fixing by Low&reverse brake at the 1st gear, this mechanical fixing device was used. This structure is not
a new concept, because this OWC already has been installed on the previous models.
ACCUMULATORS
NumberFunction Name Color
1 Low&Reverse Brake None
2 Underdrive Clutch Yellow
3 Second Brake Blue
4 Overdrive Clutch None

Objective
* Energy (hydraulic pressure) storage
* Impact and pulsation damping when solenoid valves operating
* Operation as spring element
* Smooth shifting by preventing sudden operation of clutches and brakes
TRANSFER DRIVE GEAR
With the transfer drive gear, increased tooth height and a higher contact ratio have reduced gear noise.
Also, the bearing that supports the drive gear is a preloaded type that eliminates rattle, and the rigidity of the gear
mounting has been increased by bolting the bearing directly onto the case.
OUTPUT SHAFT/TRANSFER DRIVEN GEAR
As shown in the illustration below, the transfer driven gear is press- fitted onto the output shaft, and the output shaft is
secured by a locking nut and supported by bearings.
The locking nut has a left- handed thread, and a hexagonal hole in the other end of the shaft enables the shaft to be
held in position for locking nut removal.

6c.
Driving at constant
speed of 30 km/h in 2nd
gear
d. Driving at 50 km/h in 3rd
gear with accelerator
fully closed
e. Driving at constant
speed of 50 km/h in 4th
gear (1) 100%, (2) 0%, (3)
100%
Second solenoid valve
(2) 100%, (3) 100%,
(4) 0% Overdrive solenoid valve
(1) 0km/h
(4) 50km/h Vehicle speed sensor
(4) 1,800 ~ 2,100rpm Input shaft speed sensor
(4) 1,800 ~ 2,100rpm Output shaft speed sensor
7 Selector lever position
: D (Carry out on a
flat and straight road)
a.
Accelerate to 4th gear at
a throttle position sensor
output of 1.5V
(accelerator opening
angle of 30 %).
b. Gently decelerate to a
standstill.
c. Accelerate to 4th gear at
a throttle position sensor
output of 2.5 V
(accelerator opening
angle of 50%).
d. While driving at 60 km/h
in 4th gear, shift down
to 3rd gear.
e. While driving at 40 km/h
in 3rd gear, shift down
to 2nd gear.
f. While driving at 20 km/h
in 2nd gear, shift down
to 1st gear. For (1), (2) and (3),
the reading should be
the same as the
specified output shaft
torque, and no
abnormal shocks
should occur.
For (4), (5) and (6),
downshifting should
occur immediately
after the shifting
operation is made.
Malfunction when shifting
Displaced shift points
Does not shift
Does not shift from 1 to 2 or
2 to 1
Does not shift from 2 to 3 or
3 to 2
Does not shift from 3 to 4 or
4 to 3
8 Selector lever position
: N (Carry out on a
flat and straight road)
Move selector lever to R
range drive at constant
speed of 10km/h The ratio between
input and output shaft
speed sensor data
should be the same
as the gear ratio
when reversing.Does not shift
TORQUE CONVERTER STALL TEST
This test measures the maximum engine speed when the selector lever is in the D or R position. The torque converter
stalls to test the operation of the torque converter, starter motor, one- way clutch operation, the holding performance of
the clutches, and brakes in the transaxle.
Do not let anybody stand in front of or behind the vehicle while this test is being carried out
1. Check the automatic transmission fluid level and temperature, and the engine coolant temperature.
a. Fluid level : At the HOT mark on the oil level gauge
b. Fluid temperature : 80~100°C (176~212°F)
c. Engine coolant temperature : 80~100°C(176~212°F)
2. Prevent all the wheels from moving during the test.
3. Pull the parking brake lever up, with the brake pedal fully depressed.
4. Start the engine.

2007 > 2.7L V6 GASOLINE >
SERVICE ADJUSTMENT PROCEDURE
Automatic transaxle fluid
INSPECTION 1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C].
2. Place the vehicle on a level surface.
3. Move the selector lever through all gear positions. This will fill the torque converter and the hudraulic system with
fluid and move the selector lever to the "N" (Neutral) or "P"(Park) position.
4. Before removing the oil level gauge, wipe all contaminants from around the oil level gauge. Then take out the oil
level gauge and check the condition of the fluid.
If the fluid smells as if it is burning, it means that the fluid has been contaminated by fine particles from the
bushes and friction materials, a transaxle overhaul may be necessary.
5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is low, add automatic transaxle
fluid until the level reaches the "HOT" mark.
Auto transaxle fluid:
DIAMOND ATF SP - III, SK ATF SP - III
Quantity : 8.5ℓ (9.0 US qt, 7.5 lmp.qt)
Low fluid level can cause a variety of a abnormal conditions because it allows the pump to take in air along
with fluid. Air trapped in the hydraulic system forms bubbles, which are compressable. Therefore, pressures
will be erratic, causing delayed shifting ,slipping clutches and brakes, etc. Improper filling can also raise fluid
level too high. When the transaxle has too much fluid, gears churn up foam and acuise the same conditions
which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either
case, air bubbles can cause overheating, and fluid oxidation, which can interfere with normal valve, clutch, and
brake operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken
for a leak.
6. Insert the oil level gauge(A) securely.
When new, automatic transmission fluid should be red. The red dye is added so the assembly plant can
identify it as transmission fluid and distinguish it from engine oil or antifreeze. The red dye, which is not an
indicator of fluid quality, is not permanent. As the vehicle is driven the transmission fluid will begin to look
darker. The color may eventually appear light brown.

Check the vehicle alignmnt.
● Is the alignment within specification ?
→ YES
Go to
→ NO
Adjust the alignment as necessary.
See page SS - 69 (wheel alignment).
BRAKE DRAG DIAGNOSIS Apply the brakes while driving.
● Does drift or pull occur when the brakes are applied ?
→ YES
See BR group - specification.
→ NO
If the steering wheel is in the center, the vehicle is OK.
If the steering wheel is off- center, Go to Detailed Test F.
DETAILED TEST F : STEERING WHEEL OFF- CENTER CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK THE CLEAR VISION Place the vehicle on an alignment rack.
● Is the clear vision within specification ?
→ YES
Go to F2.
→ NO
Adjust the clear vision to specification.
INSPECT THE STEERING COMPONENTS
a.Raise and support the vehicle.
b. Inspect the steering components for excessive wear or damage.
See ST group - specification.
● Are the steering components excessively worn or damaged ?
→ YES
Repair or Install new components as necessary.
→ NO
If it tracks correctly, vehicle is OK.
If it tracks incorrectly, Go to Detailed Test
DETAILED TEST G : TRACKS INCORRECTLY CONDITIONS DETAILS/RESULTS/ACTIONS
CHECK THE CASTER Place the vehicle on an alignment rack.
● Is the caster within specification ?
→ YES
Go to G2.

2007 > 2.7L V6 GASOLINE >
TROUBLESHOOTING
Symptom Probable cause Remedy
Excessive play in
steering Loose yoke plug
Retighten
Loose steering gear mounting bolts Retighten
Loose or worn tie rod end Retighten or replace as necessary
Steering wheel
operation is not
smooth (Insufficient
power assist) V- belt slippage
Readjust
Damaged V- belt Replace
Low fluid level Replenish
Air in the fluid Bleed air
Twisted or damaged hoses Correct the routing or replace
Insufficient oil pump pressure Repair or replace the oil pump
Sticky flow control valve Replace
Excessive internal oil pump leakage Replace the damaged parts
Excessive oil leaks from rack and pinion in
gear box Replace the damaged parts
Distorted or damaged gear box or valve body
seals Replace
Steering wheel does
not return properly Excessive turning resistance of tierod end
Replace
Yoke plug excessively tight Adjust
Tie rod and/or ball joint cannot turn smoothly Replace
Loose mounting of gear box mounting bracket
Worn steering shaft joint and/or Retighten
Worn steering shaft joint and/or body
grommet Correct or replace
Distorted rack Replace
Damaged pinion bearing Replace
Twisted or damaged hoses Reposition or replace
Damaged oil pressure control valve Replace
Damaged oil pump input shaft bearing Replace
Noise Hissing Noise in Steering Gear
There is some noise with all power steering systems. One of the most common is a hissing
sound when the steering wheel is turned and the car is not moving. This noise will be most
evident when turning the wheel while the brakes are being applied. There is no relationship
between this noise and steering performance. Do not replace the valve unless the "hissing"
noise becomes extreme. A replaced valve will also make a slight noise, and is not always a
solution for the condition.
Rattling or chucking
noise in the rack and
pinion Interference with hoses from vehicle body
Reposition
Loose gear box bracket Retighten
Loose tie rod end and/or ball joint Retighten
Worn tie rod and/or ball joint Replace
Noise in the oil pump Low fluid level Replenish
Air in the fluid Bleed air
Loose pump mounting bolts Retighten