ABS KIA CARNIVAL 2007 Owner's Manual

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
FRONT SUSPENSION SYSTEM
Items Specification
Type Macpherson strut
Shock Absorber Type
Gas
Stroke mm (in) 195.5 (7.70)
Expansion mm (in) 595.5 ± 3 (23.44 ± 0.12)
Compression mm (in) 400 + 3, - Free (15.75 + 3,
Free)
I.D. Color DIESEL
WHITE
GASOLINE RED
Damping force (0.3 m/s) DIESEL
Expansion N(kgf)
1265 ± 186 (129 ± 19)
Compression N (kgf) 618 ± 108 (63 ± 11)
GASOLINEy Expansion N(kgf)
980 ± 220 (100 ± 15)
Compression N (kgf) 588 ± 118 (60 ± 12)
Spring DIESEL
Free height mm (in)
418.9 (16.49)
Load(kg) I.D. Color594.8~606.7
Yellow 2 point
y
582.9~594.7 yYellow 1 point
GASOLINE Free height mm (in)
415.9 (16.37)
Load(kg) I.D. Color550.0~561.2
Green 2 point
y
538.8~549.9 Green 1 point
REAR SUSPENSION SYSTEM Items Specification
Type Multi Link
Shock Absorber Type
Gas
Stroke mm (in) 170 (6.68)
Expansion mm (in) 478.0 ± 3 (18.82 ± 0.12)
Compression mm (in) 308 + 3, - Free
(12.13 + 0.12, - Free)
I.D. Color DIESEL
WHITE
GASOLINE RED
Damping force (0.3 m/s) DIESEL
Expansion N(kgf)
1540 ± 216 (157 ± 22)
Compression N (kgf) 647 ± 127 (66 ± 13)
GASOLINE Expansion N(kgf)
1422 ± 206 (145 ± 21)
Compression N (kgf) 549 ± 108 (56 ± 11)
DIESEL Free height mm (in)
286.7 (11.29)
Load(kg) I.D. Color642.2~674.7
Yellow 2 point
y

Rear shock absorber bracket mounting bolt(to body)80 ~ 1108 ~ 1157.9 ~ 79.5
Rear shock absorber bracket mounting nut(to body) 90 ~ 1209~ 1265.1 ~ 86.8
Rear shock absorber nut (to rear knuckle) 140 ~ 16014 ~ 16101.2 ~ 115.7
Rear upper arm ball joint nut (to rear knuckle) 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear upper arm self - locking nut (to cross member) 160 ~ 18016 ~ 18115.7 ~ 130.2
Rear lower arm mounting bolt (to rear knuckle) 160 ~ 18016 ~ 18115.7 ~ 130.2
Rear lower arm mounting nut (to cross member) 200 ~ 27020 ~ 27144.7 ~ 195.3
Rear assist arm mounting bolt (to rear knuckle) 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear assist arm mounting nut (to cross member) 90 ~ 1209 ~ 1265.1 ~ 86.8
Trailing arm bracket mounting nut (to body) 80 ~ 1108 ~ 1157.9 ~ 79.5
Trailing arm self - locking nut (to rear knuckle) 80 ~ 1008 ~ 1057.9 ~ 72.3
Trailing arm mounting bolt(to bracket) 160~ 18016 ~ 18115.7 ~ 130.2
Rear stabilizer bar bracket mounting bolt(to cross member) 39 ~ 603.9 ~ 6.028.2 ~ 43.4
Rear stabilizer link self - locking nut(to trailing arm) 50 ~ 655.0 ~ 6.536.2 ~ 47.0
Wheel nut 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear cross member to body 160 ~ 18016 ~ 18115.7~130.2
Replace the self - locking nuts with new ones after removal.
LUBRICANTS
Items The Recommended Quantity
Front lower arm ball joint Boot : CGMS03 (CMS - H006)
Ball seat : CGMS02 (CMS - H006)
As required
Rear upper arm ball joint
Boot : CGMS03 (CMS - H006)
Ball seat : CGMS01 (CMS - H006)
Rear assist arm ball joint
Stabilizer link ball joint(Front Rear)

2.Remove the self - locking nut (C) from the strut assembly (B).
3. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly.
INSPECTION
1.Check the strut insulator for wear or damage.
2. Check rubber parts for damage or deterioration.
3. Compress and extend the piston rod (A) and check that there is no abnormal resistance or unusual sound during
operation.
REASSEMBLY
1.Install the spring lower pad (D) so that the protrusions (A) fit in the holes (C) in the spring lower seat (B).
2.Compress coil spring using special tool (09546- 26000).
Install compressed coil spring into shock absorber.
a.Indicated two identification color marks on the coil spring one follows model option the other follows load
classification according to the below.
Pay attention to distiuguish between the two marks and then install them.

Rear Shock Absorber

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Loosen the wheel nuts slightly.
Raise the rear of the vehicle, and make sure it is securely supported.
2. Remove the rear wheel and tire (A) from rear hub (B).
Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A).
3. Remove the rear shock absorber assembly mounting bolts (A) and nut (B) from the baby.
4.Remove the rear shock absorber assembly nut (B) from the rear knuckle, then remove the shock absorber
assembly (A).
5.Remove the rear shock absorber bracket bolt (A).

INSTALLATION
1.Install the connecting bolt (A) between the rear shock absorber and the bracket.
Tightening torque Nm(kgf.m, lb - ft) :
160 ~ 180 (16 ~ 18, 115.7 ~ 130.2)
2.Install the rear shock absorber (A) to the knuckle temporarily.
3.Install the rear shock absorber bracket mounting bolts (A) and nut (B).
Tightening torque Nm(kgf.m, lb - ft) :
Bolt : 80 ~ 110 (8 ~ 11, 59.7 ~ 79.5)
Nut : 90 ~ 120 (9 ~ 12, 65.1 ~ 86.8)

4.Install the rear shock absorber (A) nut (B) to the knuckle.
Tightening torque Nm(kgf.m, lb - ft) :
160 ~ 180 (16 ~ 18, 115.7 ~ 130.2)
5.Install the wheel and the tire (A) to the rear hub (B).
Tightening torque Nm (kgf.m, lb - ft) :
90 ~ 110 (9 ~ 11, 65.1 ~ 79.5)
Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A).
INSPECTION
1.Check the rubber parts for damage or deterioration.
2. Check the shock absorber for abnormal resistance or unusual sounds.

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 >
INSTRUCTIONS
WHEN HANDLING REFRIGERANT
1. R- 134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When
handling the refrigerant, be sure to wear gloves.
2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the
refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R- 134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F)
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R- 134a systems. If lubricants other than the recommended one used,
system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be
observed:
a. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
b. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
c. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from taking
on moisture.
d. Use the recommended lubricant from a sealed container only.
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.
WHEN REPLACING PARTS ON A/C SYSTEM
1.Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil
before making the connection.
WHEN INSTALLING CONNECTING PARTS
FLANGE WITH GUIDE PIN

volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain
from the new compressor (through the suction fitting).
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. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
d. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
e. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
f. Adjust the drive belt (Refer to HA - 14)
g. Charge the system and test its performance. (Refer to HA - 9)
INSPECTION
1.Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is
damage, replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if
it is noisy or has excessive play/drag.
3.Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the
clearance is not within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as
needed to increase or decrease clearance.
Clearance: 0.45 ± 0.1mm (0.018 ± 0.004 in.)
The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm
and 1.3mm.