engine KIA CARNIVAL 2007 Workshop Manual

30.Install the engine cover. (see 'EM' group)
When replacing the automatic transaxle, reset the automatic transaxle's values by using the High- Scan Pro.
a. Connect the Hi - Scan Pro connector to the data link connector under the crash pad and power cable to the cigar
jack under the center facia.
b. Turn the ignition switch on and power on the Hi - Scan Pro.
c. Select the vehicle's name.
d. Select 'AUTOMATIC TRANSAXLE'.
e.Select 'RESETTING AUTO T/A VALUES' and perform the procedure.
f.Perform the procedure by pressing F1 (REST).

2007 > 2.7L V6 GASOLINE >
SPECIAL TOOLS
Item(Namber&Name) Illustration Use
09452 - 21200
Oil seal installer
Oil seal installation
09200 - 38001
Engine supporting fixture
Removal and installation of transaxle
09455 - 32200
Oil seal puller
Removal of oil seal
09455 - 21000
Bearing&gear puller
Removal of taper roller vearing
09432 - 33200
plate
Removal of oil seal
09478 - 26100
Backing plate remover
Removal of 4WD coupling backing plate
09478 - 26000
Flange oil seal installer
Installation of 4WD coupling flange oil seal

2007 > 2.7L V6 GASOLINE >
SPECIFICATION
Engine type µ 2.7
Manual transaxle type M5GF2
Gear ratio 1st 3.615
2nd 1.931
3rd 1.969
4th 1.273
5th 0.974
Reverse 3.416
Final gear ratio 5.071
3.737
T/M oil capacity(ℓ) ※ 1.9 liter (2.0077US qt, 1.6718mp qt)
※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must
be set according to 'INSPECTION' or 'REPLACEMENT' procedure of the automatic transaxle fluid.
Recommended transaxle oil SAE75W/85 or API GL - 4
Check&Replenishment Every one year or every 100,000km
Replacement Private useNormal use
No service required
Severe use( ※)
Every 100,000 Km
Business use
※ Severe use(marked '※') is defined as:
1. Driving on rough road(bumpy road, gravel road, snowy road, unpaved road etc.).
2. Driving on mountain road, ascent/descent.
3. Repetition of short distance driving.
4. More than 50% operation in heavy city traffic during hot weather above 32°C(89.6°F).
5. Police car, Taxi, Commercial type operation or trailer towing, etc.
TIGHTENING TORQUE
Item Nmkgf.m lb- ft
Oil drain plug 30~353.0~3.521.7~25.3
Oil filler plug 30~353.0~3.521.7~25.3
Back up lamp switch 30~353.0~3.521.7~25.3
Control shaft assembly 10~121.0~1.2 7.2~8.7
Select lever 43~554.3~5.531.1~39.8
Shift link assembly 43~554.3~5.531.1~39.8
Transaxle mounting bracket assembly 65~856.5~8.547.0~61.5
Transaxle and enging mounting bolt 65~856.5~8.547.0~61.5
SERVICE STANDARD Item Specification [mm(inch)]

2007 > 2.7L V6 GASOLINE >
SERVICE ADJUSTMENT PROCEDURE
Transmission oil inspection and replacement
1. After parking the vehicle on a plain, stop the engine.
2. After removing the oil filler plug and washer, inspect the manual transaxle fluid condition and quantity.
3. If the manual transaxle fluid is contaminated, drain it out by removing the oil drain plug.
4. Tighten the new oil drain plug and feed manual transaxle fluid to a proper level.
TORQUE:
29.4~34.4 Nm(3.0~3.5kgf.m, 21.7~25.3lb - ft)
Oil type: SAE75W/85
Oil quantity:
1.9 liter(2.0077 US qt, 1.6718 lmp qt)
5. Retighten the oil filler plug with a new washer.
TORQUE:
29.4~34.4 Nm(3.0~3.5kgf.m, 21.7~25.3lb - ft)
Back up lamp switch inspection
1.Disconnect the back up lamp switch connector(B).
2.Inspect the continuity of the switch. When the shift lever is located in reverse range, it should be applied an electric
current.
3. Replace the back up lamp switch, if necessary.
TORQUE:
29.4~34.4 Nm(3.0~3.5kgf.m, 21.7~25.3lb - ft)

8.Remove C.S.C (Concentric Slave Cylinder) tube(A) which is being clamped by loosening the nut(B).
9.Remove the transaxle upper mounting bolts(A).
10. Support the engine and transaxle by using the special tool (09200- 38001).

19.Install the under cover(A).
20.Install the steering column joint bolt.(See ST group).
21. Install the front wheels and tires. (see SS group)
22. Install the transaxle insulator and mounting bracket (B) by tightening the bolts (A).
TORQUE:
60~80 Nm (6~8 kgf.m, 43.6~58.2 lb - ft)
23.remove the SST (09200- 38001) holding the engine and transaxle assembly.
TORQUE:
65~85 Nm (6.5~8.5kgf.m, 47.0~61.5 lb - ft)

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Driveshaft
Engine Transaxle Joint type
Max. permissible angle
Inner Outer InnerOuter
2.9 CRDi M/T
TSJ#26 BJ#2846.5° 23°
A/T UTJ- II#25 BJ#2646.5° 23°
3.8 MPI A/TUTJ- II#25 BJ#2646.5° 23°
Front hub & bearing assembly
Starting torque 1.97 Nm (20 kgf.cm, 1.45 lb - ft)
Rear hub & bearing assembly
Starting torque y 1.97 Nm (20 kgf.cm, 1.45 lb - ft)
Inner: On transaxle side
Outer : On tire side
TGHTENING TORQUE
Items NmKgf.m lb- ft
Hub nut 90 ~ 1109.0 ~ 11.0 65 ~ 80
Driveshaft lock nut 245 ~ 27524.5 ~ 27.5 177 ~ 199
Tie rod end castle nut 60 ~ 806.0 ~ 8.0 43 ~ 58
Front lower arm to knuckle bolt & nut 90 ~ 1209.0 ~ 12.0 65 ~ 87
Inner shaft bearing & bracket assembly bolts
(DSL) 43 ~ 63
4.3 ~ 6.3 31 ~ 46
Inner shaft bearing & bracket assembly bolts
(GSL) 50 ~ 65
5.0 ~ 6.5 36 ~ 47
Front caliper assembly to knuckle bolts 85 ~ 1008.5 ~ 10.0 61 ~ 72
Front strut assembly to knuckle bolts 100 ~ 12010.0 ~ 12.0 72 ~ 87
Front hub & bearing assembly to knuckle
bolts 160 ~ 180
16.0 ~ 18.0 116 ~ 130
Rear lower arm to carrier bolt & nut 160 ~ 18016.0 ~ 18.0 116 ~ 130
Rear caliper assembly to carrier assembly
bolts 50 ~ 60
5.0 ~ 6.0y 36.2 ~ 43.4
Rear hub lock nut 200 ~ 26020.0 ~ 26.0 145 ~ 188
Rear brake assembly to carrier assembly bolts 50 ~ 605.0 ~ 6.0 36 ~ 43
Carrier assembly to assist arm bolt 90 ~ 1009.0 ~ 10.0 65 ~72
Carrier assembly to upper arm bolt 90 ~ 1009.0 ~ 10.0 65 ~72
LUBRICANTS
Joint type Recommended grease Quantity

operation.
→ NO
Go toB4.
CHECK THE TRAILING ARMS
a.Inspect the trailing arm bushings for wear or damage. Check for loose
trailing arm bolts.
b. Inspect for twisted or bent trailing arms.
● Are the trailing arms loose, damaged or worn ?
→ YES
Repair or Install new components as necessary. Test the system for
normal operation.
→ NO
Suspension system is OK. Conduct diagnosis on other suspect systems.
DETAILED TEST C : WHEEL AND TIRE CONDITIONS DETAILS/RESULTS/ACTIONS
ROAD TEST THE VEHICLE
Wheel or tire vibrations felt in the steering wheel are most likely related
to the front wheel or tire. Vibration felt through the seat are most likely
related to the rear wheel or tire. This may not always be true, but it can
help to isolate the problem to the front or rear of the vehicle.
Test drive the vehicle at different speed ranges.
During the road test, if the vibration can be eliminated by placing the
vehicle in neutral or is affected by the speed of the engine, the cause is not
the wheels or tires.
● Is there a vibration and noise ?
→ YES
Go to C2.
→ NO
The wheel and tires are OK. Conduct a diagnosis on other suspect
systems.
CHECK THE FRONT WHEEL BEARINGS Check the front wheel bearings.
Refer to Wheel Bearing Check (See DS group - front axle).
● Are the wheel bearings OK ?
→ YES
Go to C3.
→ NO
Inspect the wheel bearings. Adjust or Repair as necessary. Test the system
for normal operation.
INSPECT THE TIRES
a.Check the tires for missing weights.
b. Check the wheels for damage.

a.Substitute a known good set of wheels and tires.
b. Perform a road test.
c. If the vehicle still exhibits a shake or vibration, note the vehicle speed
and/or engine rpm which it occurs.
● Is the vibration felt ?
→ YES
Engine/transmission imbalance.
See the specification of TR group, EM group, FL group and EC group.
→ NO
Install the original tire/wheel assemblies one by one, Road testing at
each step until the damaged tire(s)/wheel(s) as necessary. Test the
system for normal operation.
Wheel /tire noise, vibration and harshness concerns are directly related to vehicle speed and are not generally affected
by acceleration, coasting or decelerating. Also, out - of- balance wheel and tires can vibrate at more than one speed. A
vibration that is affected by the engine rpm, or is eliminated by placing the transmission in Neutral is not related to the
tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and
wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially
isolate a concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused by damaged or
worn tire and wheels. Perform a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and
watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions WHEEL AND TIRE DIAGNOSIS
Rapid wear at the center Rapid wear at both shoulders Wear at one shoulder
a.Center - tread down to fabric due to
excessive over inflated tires
b. Lack of rotation
c. Excessive toe on drive wheels
d. Heavy acceleration on drive a.
Under- inflated tires
b. Worn suspension components
c. Excessive cornering speeds
d. Lack of rotation a.
Toe adjustment out of specification
b. Camber out of specification
c. Damaged strut
d. Damaged lower arm
Partial wear Feathered edge Wear pattern
a.Caused by irregular burrs on
brake drums a.
Toe adjustment out of
specification
b. Damaged or worn tie rods
c. Damaged knuckle a.
Excessive toe on non- drive
wheels
b. Lack of rotation

6.Remove both sides of the lower arm (A) mounting bolts (B).
7.Remove the engine mounting bolts (A, B)