height KIA CARNIVAL 2007 Workshop Manual

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Description SpecificationsLimit
General
Type V- type, DOHC
Number of cylinder 6
Bore 86.7mm(3.4134in.)
Stroke 75mm(2.9528in.)
Total displacement 2,656cc
Compression ratio 10.4
Firing order 2 - 3 - 4 - 5 - 6 - 1
Valve timing
Intake valve Opens (ATDC) 4° ~ - 56°
Closes (ABDC) 60° ~ 0°
Exhaust valve Opens (BBDC) 46°
Closes (ATDC) 10°
Cylinder head
Flatness of gasket surface 0.03mm(0.0012in.) or less 0.05mm(0.0020in.)
Flatness of
manifold mounting Intake
0.15mm(0.0059in.) or less
Exhaust 0.15mm(0.0059in.) or less
Camshaft
Cam height LH
CamshaftIntake
44.5mm(1.7520in.)
Exhaust 44.5mm(1.7520in.)
RH
Camshaft Intake
44.5mm(1.7520in.)
Exhaust 44.5mm(1.7520in.)
Journal outer
diameter LH
CamshaftIntake
27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Exhaust 27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
RH
Camshaft Intake
27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Exhaust 27.964 ~ 27.980mm(1.1009 ~ 1.1016in.)
Bearing oil
clearance Intake
0.020 ~ 0.057mm(0.0008 ~ 0.0022in.)
Exhaust 0.020 ~ 0.057mm(0.0008 ~ 0.0022in.)
End play 0.05 ~ 0.15mm(0.0020 ~ 0.0059in.)
Valve
Valve length Intake 110.1mm(4.3346in.)
Exhaust 111.1mm(4.3740in.)
Stem outer
diameter Intake
5.965 ~ 5.980mm(0.2348 ~ 0.2354in.)
Exhaust 5.950 ~ 5.965mm(0.2343 ~ 0.2348in.)
Face angle 45° ~ 45.5°
Thickness of
valvehead(margin) Intake
1.0mm(0.0394in.)
Exhaust 1.3mm(0.0512in.)

Valve stem to valve
guide clearanceIntake
0.020 ~ 0.050mm(0.0008 ~ 0.0020in.) 0.10mm(0.0039in.)
or less
Exhaust 0.035 ~ 0.065mm(0.0014 ~ 0.0026in.) 0.13mm(0.0051in.)
or less
Valve guide
Inner diameter Intake 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Exhaust 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.)
Length Intake 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
Exhaust 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
Valve spring
Free length 46.8mm(1.8425in.)
Load Height: 35mm 180.5 ~ 199.5N(18.4 ~ 20.3Kgf, 40.6 ~ 44.8lb)
Height: 26.5mm 342 ~ 378N(34.9 ~ 38.6Kgf, 76.9 ~ 85.1lb)
Out of squareness 1.5° or less
MLA(Mechanical Lash Adjuster)
MLA outer diameter Intake 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Exhaust 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
Cylinder head
tappet bore inner
diameter Intake
30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
Exhaust 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
MLA to tappet bore
clearance Intake
0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Exhaust 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.) 0.07mm(0.0027in.)
or less
Valve clearance
Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.) 0.10 ~ 0.30mm
(0.0039 ~
0.0118in.)
Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.) 0.20 ~ 0.40mm
(0.0078 ~
0.0157in.)
Cylinder block
Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)
Flatness of gasket surface Less than 0.05mm (0.0019in.)
[Less than 0.02mm (0.0008in.) / 150x150]
Piston
Piston outer diameter 95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)
Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)
Ring groove width No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.)
Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.)
Piston O.S. 0.25mm(0.0098in.)
Piston ring
Side clearance No. 1 ring 0.04 ~ 0.08mm(0.0016 ~ 0.0031in.) 0.1mm(0.0039in.)

If the margin thickness is less than the specification, replace the valve.
Specification
Intake : 1.0mm(0.0394in.)
Exhaust : 1.3mm(0.0512.)
(4)Check the valve length.
Length
Intake : 110.1mm(4.3346in)
Exhaust : 111.1mm(4.3740in)
(5) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
(1) Check the valve seat for evidence of overheating or improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace the valve
guide first.
(3) Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out - of- square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
[Standard]
Free height : 46.8mm (1.8425in.)
Out- of- square : 1.5° or less

MLA(Mechanical Lash Adjuster)
1.Inspect MLA.
Using a micrometer, measure the MLA outside diameter.
MLA O.D.
Intake/Exhaust : 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.)
2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.
Tappet bore I.D.
Intake/Exhaust : 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.)
3. Calculate the clearance by subtracting MLA outside diameter measurement from tappet bore inside diameter
measurement.
MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.) or less
CAMSHAFT
1.Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.5mm (1.7520in.)
Exhaust : 44.5mm (1.7520in.)
If the cam lobe height is less than standard, replace the camshaft.
2. Check the cam lobe surface for wear or damage. If necessary, replace it.
3. Inspect camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.

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.

Strut and spring assembly
Spring and strut mounting
Front lower arm ball joint
Front lower arm mounting bolt
bushing
Stabilizer bar bushings
Wheel hubs and bearing
Rear suspension arms and bushings
Vehicle leans Tire/wheel
Vehicle load
Suspension components
Incorrect ride heightInflate tires to specification.
Redistribute the load as necessary.
Visually inspect the suspention
system.
Correct the ride height as necessary.
Poor steering returnability High knuckle rotating torque
AlignmentGo to detailed test E.
DETAILED TEST A : FRONT SUSPENSION NOISE CONDITIONS DETAILS/RESULTS/ACTIONS
ROAD TEST THE VEHICLE
a.Test drive the vehicle.
b. During the road test, drive the vehicle over a rough road. Determine
from which area/component the noise is originating.
● Is there a squeak, creak or rattle noise ?
→ YES
Go to
→ NO
The suspension system is OK. Conduct a diagnosis on other suspect
systems.
INSPECT THE STEERING SYSTEM a.Check the steering system for wear or damage.
Perform a steering linkage test.
Inspect the tire wear pattern.
● Are the steering components worn or damaged ?
→ YES
Repair the steering system. Install new components as necessary. Test
the system for normal operation.
→ NO
Go to
FRONT SHOCK ABSORBER/STRUT CHECK a.Check the front shock absorbers/strut mounts for loose bolts or nuts.
b. Check the front shock absorbers/struts for damage. Perform a shock
absorber check.
● Are the front shock absorbers/struts loose or damaged ?
→ YES
Tighten to specifications if loose.
Install new front shock absorbers/struts if damaged. Test the system for
normal operation.
→ NO
Go to
CHECK THE FRONT SPRINGS Check the front spring and front spring mounts/brackets for wear or
damage

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

Spring610.0~642.2
Yellow 1 point
GASOLINE Free height mm (in)
291.1(11.46)
Load(kg) I.D. Color623.6~653.0
White 2 point
y
594.2~623.6 White 1 point
WHEELS AND TIRES Items Specification
Tire Size 225/70 R16
235/60 R17
Wheel Size Steel
6.5J×16
Aluminium 6.5J×16
6.5J×17
Tire Pressure KPa (kg/cm², psi) y
Front Rear
225/70 R16 2.4(35)2.4(35)
235/60 R17 2.4(35)2.4(35)
WHEEL ALIGNMENT Items FrontRear
Camber 0° ± 30´- 6´ ± 30´
Caster to Ground
3°46´ ± 30´ -
to Body 4°40´ -
Toe- in mm(in) 0 ± 2(0 ± 0.0787)2.6 ± 2(0.1024 ± 0.0787)
King pin angle 12°27´±30´-
Tread mm(in) 1685(66.34)1685(66.34)
TIGHTENING TORQUE
FRONT SUSPENSION
Items Nmkgf.m lb- ft
Front strut assembly mounting nut(to body) 45 ~ 604.5 ~ 6.032.5 ~ 43.4
Front strut assembly self - locking nut 60 ~ 706 ~ 743.4 ~ 50.6
Front strut assembly mounting bolt(to knuckle) 100 ~ 12010 ~ 1272.3 ~ 86.8
Front lower arm ball joint mounting bolt(to knuckle) 90 ~ 1209 ~ 1265.1 ~ 86.8
Front lower arm bushing(A) mounting bolt(to subframe) 160 ~ 18016 ~ 18115.7 ~ 130.2
Front lower arm bushing(G) mounting bolt(to subframe) 160 ~ 18016 ~ 18115.7 ~ 130.2
Front stabilizer link self - locking nut 100 ~ 12010 ~ 1272.3 ~ 86.8
Front stabilizer bar bracket mounting bolt(to Subframe) 39 ~ 603.9 ~ 6.028.2 ~ 43.4
Wheel nut 90 ~ 1109 ~ 1165.1 ~ 79.5
REAR SUSPENSION Items Nmkgf.m lb- ft

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Item Specification
Master cylinder
· Type
· I.D. mm(in)
· Piston stroke mm(in)
· Fluid level warning sensor Tandem type
26.99/(1.063)
30(1.18)
Provided
Brake booster
· Type
· Boosting ratio 8 + 9 in Tandem
9.0 : 1
Front brake(Disc)
· Type
· Disc O.D.
· Disc thickness
· Pad thickness
· Cylinder type
· Cylinder I.D. Floating type with ventilated disc
298 mm (11.73 in)
28 mm (1.10 in)
10.5 mm (0.41 in)
Double piston
Ø48 mm (Ø1.89 in)
Rear brake(Disc)
· Type
· Disc O.D.
· Disc thickness
· Pad thickness
· Cylinder type
· Cylinder I.D Floating type with solid disc
302 mm (11.89 in)
12 mm (0.47 in)
10 mm (0.39 in)
Single piston
Ø42.9 mm (Ø1.69 in)
Parking brake
· Type
· Actuation
· Drum DIH(Drum in hat)
Foot brake
Ø190 mm (Ø7.48 in)
O.D=Outer Diameter
I.D=Inner Diameter
ABS : Anti- lock Brake System
ESP : Electronic Stability Program
SERVICE STANDARD
Items Standard value
Brake pedal height 192.4 mm(7.57 in)
Brake pedal full stroke 122 mm (4.8 in)
Adjust Brake pedal full stroke 60 mm (2.36 in)
Brake pedal free play 3 ~ 8 mm(0.11 ~ 0.31 in)
Stop lamp switch outer case to pedal stopper clearance 1.0 ~ 1.5 mm (0.04 ~ 0.06 in)
Booster push rod to master cylinder piston clearance 0.6 ~ 1.7(0.02 ~ 0.07 in)(at 500 mmHg)
Parking brake pedal stroke when pedal assembly is depressed with
294N (30kgf, 66lb force) 145 mm (5.71 in) above
Front disc brake pad thickness 10.5 mm (0.41 in)
Front disc thickness 28 mm (1.10 in)
Rear disc brake pad thickness 10 mm (0.39 in)
Rear disc brake disc thickness 12 mm (0.47 in)
Rear parking brake liner thickness 4 mm (0.16 in)

2007 > 2.7L V6 GASOLINE >
Operation and Leakage Check
Check all of the following items:
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.
Piston cup and pressure cup
inspection (B) a.
Check brake operation by applying the brakes. Look for damage or signs of fluid
leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
b. Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
is damaged or leaking.
Caliper piston seal and
piston boots (D) Check brake operation by applying the brakes.
Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry out the following tests
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains
unchanged, thebooster is inoperative.