2007 KIA CARNIVAL radiator cap

No. 2 ring0.03 ~ 0.07mm(0.0012 ~ 0.0027in.) 0.1mm(0.0039in.)
Oil ring 0.06 ~ 0.15mm(0.0024 ~ 0.0059in.) 0.2mm(0.0079in.)
End gap No. 1 ring 0.15 ~ 0.30mm(0.0059 ~ 0.0118in.) 0.6mm(0.0236in.)
No. 2 ring 0.30 ~ 0.45mm(0.0118 ~ 0.0177in.) 0.7mm(0.0275in.)
Oil ring 0.20 ~ 0.70mm(0.0078 ~ 0.0275in.) 0.8mm(0.0315in.)
Piston ring O.S. 0.25mm(0.0098in.)
Piston pin
Piston pin outer diameter 21.001 ~ 21.007mm(0.8268 ~ 0.8270in.)
Piston pin hole inner diameter 21.014 ~ 21.023mm(0.8273 ~ 0.8277in.)
Piston pin hole clearance 0.007 ~ 0.022mm(0.0003 ~ 0.0009in.)
Connecting rod small end inner diameter 20.974 ~ 20.985mm(0.8257 ~ 0.8262in.)
Connecting rod small end hole clearance 0.016 ~ 0.033mm(0.0006 ~ 0.0013in.)
Connecting rod
Connecting rod big end inner diameter 51.000 ~ 51.018mm(2.0079 ~ 2.0086in.)
Connecting rod bearing oil clearance 0.018 ~ 0.036mm(0.0007 ~ 0.0014in.)
Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.) 0.4mm(0.0157in.)
Crankshaft
Main journal outer diameter 61.982 ~ 62.000mm(2.4402 ~ 2.4409in.)
Pin journal outer diameter 47.982 ~ 48.000mm(1.8891 ~ 1.8898in.)
Main bearing oil clearance 0.004 ~ 0.022mm(0.0002 ~ 0.0009in.)
End play 0.07 ~ 0.25mm(0.0028 ~ 0.0098in.) 0.30mm(0.0118in.)
Oil pump
Relief valve opening pressure 490.33 ~ 588.40kPa(5.0 ~ 6.0kgf/cm², 71.12 ~
85.34 psi)
Engine oil
Oil quantity (Total) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil pan) 4.2 L (4.43 US qt, 3.69 lmp qt)
Oil quantity (Drain and refill including oil
filter) 4.5 L (4.75 US qt, 3.95 lmp qt)
Oil quality ABOVE API SJ / SL or SAE 5W- 20
Oil pressure 130kPa(1.32kgf/cm²,18.77psi) [at
1000rpm,110°C(230°F)]
Cooling system
Cooling method Forced circulation with electrical fan
Coolant quantity 8.2~8.3L(8.66~8.77U.S.qts,7.22~7.30lmp.qts)
Thermostat Type Wax pellet type
Opening temperature 82±2°C (179.6±35.6°F)
Fully opened
temperature 95°C (203°F)
Full lift 10mm (0.3937in.) or more
Radiator cap Main valve opening
pressure 93.16 ~ 122.58kpa(0.95 ~ 1.25 kg/cm², 13.51 ~
17.78psi)

2007 > 2.7L V6 GASOLINE >
REMOVAL
WATER PUMP
1. Drain the engine coolant.
System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant,
remove the cap only when the engine is cool.
2. Remove drive belt(A).
3.Remove the timing belt.
4. Remove the water pump(A) and gasket(B).
WATER TEMPERATURE CONTROL ASSEMBLY
1.Drain the engine coolant.
2. Remove the air cleaner assembly.
3. Disconnect the radiator upper and lower hose(A, B).

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.

13.Install the radiator cap and fill the reservoir tank to the "MAX"(or "F") line with coolant.
14. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
15. Stop the engine and wait until coolant gets cool.
16. Repeat 10 to 15 until the coolant level doesn't fall any more, bleeding air out of the cooling system.
Check the coolant level again in the reservoir tank for 2 ~ 3 days after replacing coolant.
CAP TESTING
1.Remove the radiator cap, wet its seal with engine coolant, and install it to a pressure tester.
2.Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

2007 > 2.7L V6 GASOLINE >
INSPECTION
1.Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with
compressed air. If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.
REPLACEMENT
CONDENSER ASSEMBLY
1. Recover the refrigerant with a recovery/ recycling/ charging station (Refer to HA - 8).
2. Disconnect the negative ( - ) battery terminal.
3. Remove the radiator. (Refer to EM group)
4. Remove 2 bolts, and then remove the condenser (A) by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.
5.Install in the reverse order of removal, and note these items :
a. If you're installing a new condenser, add refrigerant oil ND- OIL8.
b. Replace the O - rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them.
Be sure to use the right O - rings for R- 134a to avoid leakage.
c. Be careful not to damage the radiator and condenser fins when installing the condenser.
d. Be sure to install the lower mount cushions of condenser securely into the holes.
e. Charge the system, and test its performance. (Refer to HA - 9)
DESICCANT
1.Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser.
TORQUE: 20~25N.m (2.0~2.5kgf•m, 14.5~18.2lb - ft)

2.Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged
bottom cap filter.
3.Apply air conditioning compressor oil along the O - rings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed
to air for use.
5. Install the new bottom cap to the condenser.
a.Always replace the desiccant and bottom cap at the same time.
b. Replace the O - rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O - rings for R- 134a to avoid leakage.
c. Be careful not to damage the radiator and condenser fins when installing the condenser.
d. Be sure to install the lower mount cushions of condenser securely into the holes.
e. Charge the system, and test its performance. (Refer to HA - 10)

2007 > 2.7L V6 GASOLINE >
REPLACEMENT
1.Disconnect the negative ( - ) battery terminal.
2. Recover the refrigerant with a recovery/ recycling/ charging station. (Refer to HA - 8)
3. When the engine is cool, drain the engine coolant from the radiator.
4. Remove the bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
5.Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let
coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
6. Remove the crash pad (Refer to BD group).
7. Remove the cowl cross bar assembly. (Refer to BD group)
8. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator
temperature sensor.
9. Remove the heater & blower unit after loosening 3 mounting bolts.