engine KIA CARNIVAL 2007 Workshop Manual

13OIL TEMPERATURE °C40°CCurrent Oil temperature 80°C
14 SHIFT POSITION N,P,REV/1st G/…/5th
G D
Current shift position P, N
15 SELECT LEVEL P,N/R/D/SPORTS DCurrent shift lever position P, N
16 A/CON SWITCH OFF/ON/- /NOT
SUPP OFF
-
17 IDLE STATUS OFF/ON/- /NOT
SUPP ON
When idling, ON
18 BRAKE SWITCH OFF/ON/- /NOT
SUPP ON
When braking, ON
19 AUTO CRUISE
SWITCH OFF/ON/- /NOT
SUPP
20 AUTO CRUISE
RELEASE ―
―
21 SPORT MODE
SELECT SW OFF/ON/- /NOT
SUPP ON
When selecting sport mode, ON
22 SPORT MODE UP SW OFF/ON/- /NOT
SUPP ON
When Selecting Sport mode up, ON
23 SPORT MODE DOWN
SW OFF/ON/- /NOT
SUPP ON
When selecting sport mode down,
ON
24 A/T CONTROL RELAY
VOLT V
12.9V 0V
25 ENGINE TORQUE %20%
26 HIVEC MODE A/B/C/D/E/F/G/H/I/J/K FA/B/C/D is control mode, F is
release mode F
HIVEC - SAT(SIEMENS ADAPTIVE TRANSMISSION CONTROL) Mode (Shift Patten) Shift patten Description(Help)SCAN DISPLAY
ECONOMY Economy Driver shift patten for flat road A
MEDIUM Shift patten for medium road B
SPORTS Shift patten for sport road C
LOAD 1 Shift patten for low land, slow grade and slope D
LOAD 2 Shift patten for low land, steep grade and slope E
LOAD 3 Shift patten for downhill road F
LOAD 1 HI ALT Shift patten for high land, steep grade and slope G
LOAD 2 HI ALT Shift patten for low land, steep grade and slope H
HI TEMP Shift patten for high temperture ATF I
WARM UP Shift patten for exhaust gas decrease J
HOLD Shift patten for when hold, switch on K
Actuator inspection NO ITEM NAME Actuator DrivingCondition
1 LR SOLENOID(SCSV A) 1. IG Key ON
2. Inhibitor SW normal
3. P range
2
UD SOLENOID(SCSV B)

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

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.

5.Move the selector lever to the "D" position, fully depress the accelerator pedal and take a reading of the maximum
engine speed at this time.
Stall speed : 2,100~2,900rpm
a.The throttle should not be left fully open for any more than five seconds.
b. If carrying out the stall test two or more times, move the selector lever to the "N" position and run the
engine at 1,000 r/min to let the automatic transaxle fluid cool down before carrying out subsequent tests.
6. Move the selector lever to the "R" position and carry out the same test again.
TORQUE CONVERTER STALL TEST CONCLUSION
1.Stall speed is too high in both "D" and "R" ranges
a. Low line pressure
b. Low & reverse brake(B) slippage
2. Stall speed is to high in "D" range only
a. Underdrive clutch(C) slippage
3. Stall speed is too high in "R" range only
a. Reverse clutch(A) slippage
4. Stall speed too low in both "D" and "R" ranges
a. Malfunction of torque converter(D)
b. Insufficient engine output
HYDRAULIC PRESSURE TEST
1.Warm up the engine until the automatic transaxle fluid temperature is 80- 100°C.
2. Lift up the vehicle so that the wheels are free to turn.
3. Connect the special tool (oil pressure gauge) to each pressure discharge port.
4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table,
and check that the measured values are within the standard value ranges.
5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis
table.

STANDARD HYDRAULIC PRESSURE TESTMeasurement condition Standard hydraulic pressure kPa (psi)
Selector lever
position Shift
position Engine
speed(rpm) Under
drive
clutch
pressure Reverse
clutch
pressure Overdrive
clutch
pressure Low&reverse
brake
pressure Second
brake
pressure Damper
clutch
Apply
pressure (DA) Damper
clutch
Release
pressure (DR)
P -2,500 ---260- 340
(38- 50) -
--
R Reverse 2,500 -1,270-
1,770
(185 - 256) -
1,270- 1,770
(185 - 256) -
--
N -2,500 ---260- 340
(38- 50) -
--
1st gear 2,500430- 510
(62- 74) -
-1,010- 1,050
(146 - 152) -
--
2nd gear 2,500430- 510
(62- 74) -
- -430- 510
(62- 74) -
-

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.

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.

13.Remove the starter motor by disconnecting the connector. (see EE group)
14. Using the SST(09200- 38001), hold the engine and transaxle assembly safely.
15.Remove the transaxle insulator mounting (B) bolts (A).
16.Remove the front wheels. (see SS group)
17. Lift up the vehicle.
18. Remove the power steering column joint bolt and the VRS connector (A). (see ST group)

29.Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.
e. Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent
corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle lower mounting bolts (B- 4EA).
TORQUE:
65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb - ft)
3. Install the drive plate bolts (A) by turning the timing gear.
TORQUE:
46~53 Nm(4.6~5.3 kgf.m, 33.3~38.3 lb - ft)
4.After removing a jack, insert the drive shafts. (see DS group)
5. Install the sub frame. (see SS group).
6. Tighten the roll stopper mounting bolts.
TORQUE:
90~110 Nm(9~11 kgf.m, 65.1~79.5 lb - ft)
7. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)

13.Tighten the transaxle mounting bolts (A).
TORQUE:
65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb - ft)
14.Remove the SST (09200- 38001) holding the engine and transaxle assembly.
15.Install the starter motor. (see EE group).
TORQUE:
65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb - ft)
16. Connect the power steering pressure tube (A) to the power steering oil pump.