2007 KIA CARNIVAL stop start

ClassSize code Piston outer diameter
A A86.67 ~ 86.68mm
(3.4122 ~ 3.4126in.)
B -86.68 ~ 86.69mm
(3.4126 ~ 3.4130in.)
C C86.69 ~ 86.70mm
(3.4130 ~ 3.4134in.)
8. Select the proper piston related to the cylinder bore class.
Clearance : 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
CYLINDER BORING
1.The over size piston is chosen on the maximum inner diameter of the cylinder.
The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.
3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 ~ 0.04mm(0.0008~0.0016in.)[clearance] -
0.01mm(0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
Bore the cylinders in firing order to prevent the cylinders from be twisted by high temperature.
5. Stop boring and start horning for the proper clearance.
6. Measure the clearance between a piston and a cylinder.
Specification
0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
Bore all the cylinders with the same over size.
PISTON AND RINGS
1.Clean pistons.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the
piston.

2007 > 2.7L V6 GASOLINE >
ON-VEHICLE INPECTION
a.Check that the battery cables are connected to the correct terminals.
b. Disconnect the battery cables when the battery is given a quick charge.
c. Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE
1.If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative ( - ) and positive (+) terminals of the battery.
Standard voltage : 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.
CHECK THE BATTERY TERMINALS AND FUSES
1.Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.
INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should
be replaced.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
1.Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT
1.Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.
PREPARATION

MODE 1FORCED ENGINE
SHUTDOWN Engine stop algorithm procedure
a. Fatal PCM internal programming error
b. Faulty intake system or throttle body
MODE 2 FORCED IDLE &
POWER
MANAGEMENT Forced idle state controlled by
fuel quantity regulation and
ignition timing adjustment a.
ETC system can't control engine power
via throttle device
b. Disabled throttle control or broken throttle
position information
MODE 3 FORCED IDLE Forced idle state and no response
for accelerator activation a.
No information about the accelerator
position
a. Malfuctioning APS 1 and 2, faulty A/D
converter or internal controller
MODE 4 LIMIT
PERFORMANCE & POWER
MANAGEMENT Engine power is determined by
accelerator position and idle
power requirement (Limited
vehicle running)
a.
ETC system can't securely control engine
power
MODE 5 LIMIT
PERFORMANCE a.
Engine power varies with
accelerator position, but driver
perceives lack of engine
power.
b. MIL ON (Normal vehicle
running) a.
Not reliable accelerator position signal or
bad maximum power generation
a. Faulty APS, ignition voltage or internal
controller
MODE 6 NORMALNormal
COMPONENT INSPECTION
1.Connect a scantool on Diagnoisis Link Connector (DLC).
2. Start engine and check output voltages of TPS 1 and 2 at C.T and W.O.T.
Condition Output Voltage (V)
TPS 1 TPS 2
C.T 0.25 ~ 0.9V Min. 4.0V
W.O.T Min. 4.0V 0.25 ~ 0.9V
3. Turn ignition switch OFF and disconnect the scantool from the DLC.
4. Disconnect ETC module connector and measure resistance between ETC module terminals 4 and 1 (TPS 1).
5. Measure resistance between ETC module terminals 7 and 6 (TPS 2).
Specification: Refer to SPECIFICATION.
ETC MOTOR
1.Disconnect ETC module connector and measure resistance between ETC module terminals 5 and 8.

32ND SOLENOID(SCSV C)
Solenoid valve driver for 5sec.3. P range
4. Vehicle speed 0km/h
5. Engine stop
6. No failure
7. TPS < 1V
4
OD SOLENOID(SCSV D)
5 TORQUE CONVERTER SOLENOID VALVE
6 A/T CONTROL RELAY OFF for 3 sec. -
7 INTELLIGENT SHIFT PROHIBIT Prohibit until IG off -
8 CLEAR LEARNING VALUE --
ROAD TEST
No.Condition OperationJudgment value Check item
1 Ignition switch : OFF
Ignition switch
(1) ON Battery voltage (mV)
Control relay
2 a.
Ignition switch :
ON
b. Engine : Stopped
c. Selector lever
position : P Selector lever position
(1) P, (2) R, (3) N, (4) D
(1) P, (2) R, (3) N, (4)
DTransaxle range switch
Accelerator pedal
(1) Released
(2) Half depressed
(3) Depressed (1) 400~1,000 mV
(2)Gradually rises
from (1)
(3) 4,500~5,000 mVThrottle position sensor
Brake pedal
(1) Depressed
(2) Released (1) ON
(2) OFF
Brake switch
3 a.
Ignition switch : ST
b. Engine : Stopped Starting test with lever P or
N range
Starting should be
possibleStarting possible or
impossible
4 Warming up
Drive for 15 minutes or
more so that the automatic
fluid temperature becomes
70~90°C Gradually rises to
70~90°C
Oil temperature sensor
5 a.
Engine : Idling
b. Selector lever
position : N A/C switch
(1) ON
(2) OFF
(1) ON
(2) OFF
Triple pressure switch
Accelerator pedal
(1) Released
(2) Half depressed (1) ON
(2) OFF
Idle position switch
(1) 600~900 rpm
(2) Gradually rises
from (1)
(1) Data changes Communication with
engine - ECU
Selector lever position
(1) N→D
(2) N→R Should be no
abnormal shifting
shocks
Time lag should be
within 2 secondsMalfunction when starting
Selector lever position
: N (Carry out on a
flat and straight road) Selector lever position and
vehicle speed
a. Idling in 1st gear
(Vehicle stopped)
b. Driving at constant
speed of 20 km/h in 1st
gear (2) 1st, (4) 3rd, (3)
2nd, (5) 4th
Shift condition
(2) 0%, (4) 100%, (3)
100%, (5) 100% Low and reverse solenoid
valve
(2) 0%, (4) 0%, (3)
0% Underdrive solenoid valve

REPLACEMENT
If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following
procedure.1. Disconnect the hose which connects the transmission and the oil cooler which is within the radiator only in 2.4L
engine(3.3L- the oil cooler is separated).
2. Start the engine and let the fluid drain out.
Running conditions : "N" range with engine idling.
The engine should be stopped within one minute after it is started. If the fluid has all drained out before then,
the engine should be stopped at that point.
3. Romove the drain plug(A) from the bottom of the transmission case to drain the fluid.
4.Install the drain plug via the gasket, and tighten it to the specified torque.
TORQUE :
40~50Nm (4.0~5.0 kgf.m, 29~36 lb - ft)
5. Pour the new fluid in through the oil filler tube.
Stop pouring if the full volume of fluid cannot be poured in.
6. Repeat the procedure in step (2).
Check the old fluid for contamination. If it has been contaminated, repeat the steps (5) and (6).
7. Pour the new fluid in through the oil filler tube.
8. Reconnect the hose which was disconnected in step (1) above and firmly replace the oil level gauge.(In case of
this "replace", this means after wiping off any dirt around the oil level gauge, insert it into the filler tube.)
9. Start the engine and run it at idle for 1~2 minutes.
10. Move the select lever through all positions, and then move it to the "N" position.
11. Drive the vehicle until the fluid temperature rises to the normal temperature (70~80°C), and then check the fluid
level again. The fluid level must be at the HOT mark.
12. Firmly insert the oil level gauge(A) into the oil filler tube.

CHECKING POWER STEERING BELT TENSION
Refer to EM group(Timing system).
CHECKING POWER STEERING FLUID LEVEL
1.Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the
fluid temperature to 50- 60°C (122 - 140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counter- clockwise several times.
4. Make sure that there is no foaming or cloudiness in the reservoir fluid.
5. Stop the engine and check for any difference in fluid level between a stationary and a running engine.
a.If the fluid level varies 5 mm (0.2 in) or more, bleed the system again.
b. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
c. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve, and
lead to decreased durability of the pump.
REPLACING POWER STEERING FLUID
1.Jack up the front wheels and support them with jackstands.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.
3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Remove the fuel pump fuse, then start the engine and wait for the engine to stall. Next, while operating the starting
motor intermittently, turn the steering wheel all the way to the left and then to the right several times to drain the
fluid.
5. Connect the return hoses, then fill the oil reservoir with the specified fluid.
6. Reinstall the fuel pump fuse.
7. Start the engine. Check for oil leakage.
8. Stop the engine.
9. Bleed the system.
Power steering fluid type : PSF - 3
Total quantity : Approx 1.1 liter
AIR BLEEDING
1.Remove the fuel pump fuse, then start the engine and wait for the engine to stall. Next, while operating the starting
motor intermittently (for 15 ~ 20 seconds), turn the steering wheel all the way to the left and then to the right five or
six times.

a.During air bleeding, replenish the fluid supply so that the level never falls below the lower position of the
filter.
b. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid. Be
sure to do the bleeding only while cranking.
c. Reinstall the fuel pump fuse, and start the engine(idling).
d. Turn the steering wheel to the left and the right until there are no air bubbles in the oil reservoir.
Do not hold the steering wheel turned all the way to either side for more than ten seconds.
e. Confirm that the fluid is not milky, and that the level is up to the position specified on the level gauge.
f. Confirm that there is little change in the surface o the fluid when the steering wheel is turned left and right.
a. If the surface of the fluid changes considerably, air bleeding should be done again.
b. If the fluid level rises suddenly when the engine is stopped, it indicates that there is still air in the
system.
c. If there is air in the system, a jingling noise may be heard from the pump and the control valve
may also produce unusual noises. Air in the system will shorten the life of the pump and other
parts.
OIL PUMP PRESSURE TEST (OIL PUMP RELIEF PRESSURE)
1.Disconnect the pressure hose from the oil pump. Connect the special tool between the oil pump and pressure hose
as illustrated.
2. Bleed the air, and then start the engine and turn the steering wheel several times so that the fluid temperature
rises to approximately 50°C (122°F).
3. Set the engine speed to 1,000 rpm.
4. Close the shut- off valve of the special tool and measure the fluid pressure to confirm that it is within the range.
standard vaule :
Relief pressure: 90 +3/- 2 kgf/cm²
Don’t keep the shut- off valve on the pressure gauge closed for longer than seconds.

2007 > 2.7L V6 GASOLINE >
INSPECTION
Oil Specification
1. The HFC- 134a system requires synthetic (PAG) compressor oil whereas the R- 12 system requires mineral
compressor oil. The two oils must never be mixed.
2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
Handling of Oil
1.The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC - 134a
Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.
Compressor oil check
The oil used to lubricate the compressor is circulating with the refrigerant.
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the
original amount of oil.
Oil total volume in system:
120±10cc (4.05±0.34 fl.oz)
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of
oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the following amount of oil to the component parts to be installed.
Component parts to be installed Amount of Oil
Evaporator 50 cc (1.70 fl.oz)
Condenser 30 cc (1.02 fl.oz)
Receiver/dryer 30 cc (1.02 fl.oz)
Refrigerant line (One piece) 10 cc (0.34 fl.oz)
For compressor replacement, subtract the volume of oil drained from the removed compressor from the specified
volume, and drain the calculated volume of oil from the new compressor:
The specified volume - volume of removed compressor = volume to drain from the new compressor.
Even if no oil is drained from the removed compressor, don’t drain more than 50cc from new compressor.