fuel pump KIA CARNIVAL 2007 User Guide

64A/C Compressor Relay control
output A/C OFF
DCBattery Voltage
13.97V
A/C ON Max. 1.0V175mV
65 Cooling Fan [Low] control output Fan OFF
DCBattery Voltage
13.77V
Fan ON Max. 1.0V175mV
66 Cooling Fan [High] control output Fan OFF
DCBattery Voltage
13.57V
Fan ON Max. 1.0V- 25mV
67 Variable Intake Solenoid Valve
#2 control output Active
DCMax. 1.0 V
13.77
Inactive Battery Voltage- 25mV
68 Throttle Position Sensor signal
(PWM) output
Idle
PulseHi: Battery Voltage
13.37V
Lo: 0 ~ 0.5 V - 25mV
69 Cruise "MAIN" lamp control
output Cruise OFF
DCBattery Voltage
12.37V
Cruise ON Max. 1.0V- 25mV
70 Fuel Pump Relay control output Relay OFF
DCBattery Voltage
12.57V
Relay ON Max. 1.0V- 25mV
71 Variable Intake Solenoid Valve
#1 control output Active
DCMax. 1.0 V
175mV
Inactive Battery Voltage13.77V
72 Immobilizer lamp control output Lamp OFF
DCBattery Voltage
12.77V
Lamp ON Max. 1.0V- 25mV
73 - yy y y
74 - yy y y
75 - yy y y
76 - yy y y
77 - yy y y
78 Purge Control Solenoid Valve
control output Inactive
PulseHi: Battery Voltage
13.83V
Active Lo: Max. 1.0V31.54mV
79 Wheel Speed Sensor [Low]
signal input y
y y y
80 Wheel Speed Sensor [High]
signal input y
y y y
CONNECTOR [C151- 2] Pin
No. Description
ConditionType LevelTest Result
1 ETC Motor [- ] control output IdlePulseHi: Battery Voltage
14.07V
Lo: Max . 1.0V - 125mV
2 ETC Motor [+] control output IdlePulseHi: Battery Voltage
14.07V
Lo: Max . 1.0V - 325mV
3 - yy y y
4 CVVT Oil Temperature Sensor
signal input Idle
Analog 0 ~ 5.0V 282mV at 96°C
5 - yy y y
6 - yy y y
7 Engine Coolant Temperature
Sensor signal input Idle
Analog 0 ~ 5.0V 1.88V

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Preparation
(1) Remove the 2nd seat(s) (Refer to "BD" group in this WORKSHOP MANUAL).
(2) Remove the striker cover (A).
(3) Remove the Service Cover (B).
(4)Disconnect the Fuel Pump Connector (A).
(5)Start the engine and wait until fuel in fuel line is exhausted.
(6) After the engine stalls, turn the ignition switch OFF.
2. Lift the vehicle and support it with a jack.

Fuel Pump

2007 > 2.7L V6 GASOLINE >
REMOVAL(INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR)
1.Preparation
(1) Remove the 2nd seat(s) (Refer to "BD" group in this WORKSHOP MANUAL).
(2) Remove the striker cover (A).
(3) Remove the Service Cover (B).
(4)Disconnect the Fuel Pump Connector (A).
(5)Start the engine and wait until fuel in fuel line is exhausted.
(6) After the engine stalls, turn the ignition switch OFF.
2. After disconnecting the fuel feed quick connector (A) and unscrewing the the eight screws (B), remove the fuel
pump assembly.

INSTALLATION
1.Install the Fuel Pump assembly according to the reverse order of "REMOVAL" procedure.
Fuel Pump assembly mounting bolts :
2.0 ~ 2.9 N·m (0.2 ~ 0.3 kgf·m, 1.4 ~ 2.2 lbf·ft)

2007 > 2.7L V6 GASOLINE >
Description
The automatic transmission is a combination of 3 - element 2 - phase 1 - stage torque converter and double shaft
electrocally - controlled unit which provides 4 speeds forward and 1 reverse. To improve the efficiency of power
transmission, the line pressure control was changed applying “Variable Force Solenoid (VFS) valve” on this model.
However, adopting VFS on this model, the line pressure is variably changed according to TPS and the vehicle speed,
this will enable more improved efficiency of power transmission and fuel consumption.
Characteristics
Some of the characteristics include:
▶Different power transfer
▶Different component layout
▶New shift logic(HIVEC) to improve shift feeling
▶Position of Valve Body
▶Variable shift pattern
▶Communication protocol and method
▶Step gate type shift lever.
Item Details
Weight Reduction 1. Aluminum oil pump
a. 2.3kg Approx
2. Pressed parts a. Retainer and hub of brakes and clutches
b. Carrier of planetary gear set
Better shift quality 1. Independent control of clutches and brakes enabled better control of
hydraulic pressure and skiped shifts (4 to 2, 3 to 1)
2. During N to D or N to R shift, feedback control adopted.
3. When starting from Creep condition, reduction of shock.(Creep condition is
controlled with 1st gear)
4. Solenoid valve frequency is increased for more accurate control. 35Hz to
61.3Hz except DCCSV that is 35Hz and VFS that is 600Hz.
5. HIVEC adoption for better shift feeling.
6. Variable shift pattern.
Increase in Power train efficiency 1. Fully Variable Line Pressure
2. VFS(Variable Force Solenoid)
- Manual shifting possible
- Step gate type shift lever

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.

3.The two coolant temperature sensors are installed to the heater inner. The sensor valves determine heater
operation.
4. One of the temperature sensors functions to prevent the heater from overheating.
If the sensor temperature valve exceeds 125°C, the fuel will be cut and the heater will be deactivated by the
determination of the overheating of the heater.
The other temperature sensor determines the operation mode of the fuel fired heater.The temperature of this
sensor enables to activate the heater at full load(5kw) or half load(2.5kw).
• The coolant temperature shown on the above Figure is the value of the inner sensor and the actual coolant
temperature is higher about 5°C ~7°C than the above value.
OPERATION
Switch on/ Operation start
The fuel fired heater is operated when the coolant temperature is below 68°C and the ambient temperature is below
2°C after starting the engine.
At this time, the glow plug and combustion air fan are operated first and after 30 seconds, the dosing pump is
operated with stopping the combustion fan for 3 seconds.
After that, the operation of the fan increases continuously until it approaches to full load within 56 seconds. If fuel
supply reaches to full load the glow plug does not operate and the operation of the fan reaches to full load.
After that the glow plug monitors ignition condition as a flame sensor for 45 seconds.
The above operation procedure is done automatically and in case the ignition fails, the above operation will be done
again automatically.
If the condition of ignition failure sustains continuously, fuel supply and fan operation will be stopped and error codes
will be stored to find cause of failure.
Generally, the cause of ignition failure during combustion is caused by the automatic re- operation of the above
procedure.
Operation for heating
The fuel fired heater operates at full load when the coolant temperature is below 68°C and the ambient temperature is
below 2°C after starting the engine.
It operates at half load when the coolant temperature is 74°C and it operates at idle mode when the coolant
temperature is 78°C.
The fuel fired heater during the transformation process does a cleaning function from the half mode to the idle mode.
At idle mode, all components do not work.
The fuel fired heater operating at idle mode turns into the half load when the coolant temperature is 74°C. At this time,
if the coolant temperature drops again below 68°C, the heater operates with full load and turns into the idle mode if
the temperature is 78°C.
This serial operating process is performed automatically.
Key switch off / Operation stop
The fuel fired heater ECU stops the operation of the fuel pump and cuts fuel supply when shutting off the engine
during the heater operation.
The heater conducts cleaning operation at this time.
This is a process of burning the fuel completely supplied in the heater inner.
In this process, the glow plug and combustion air fan are operated.

2007 > 2.7L V6 GASOLINE >
INSPECTION
OPERATION TEST
Fuel-fired heater operation test by force using Hi-Scan
1. Start the engine.
2. Connect the Hi - Scan to the vehicle.
3. Select "SORENTO" and then select "FUEL FIRED HEATER".
4. Select "04. ACTUATION TEST" mode.
5. Select "PREFILLING + HEATING" to conduct the performance test after replacing the fuel fired heater system.
Fuel supply and heating will be initiated if the "F1 key STRT" is pressed.
However, a repair or replacement of the components related to the fuel line system in the fuel- fired heater were not
done, operate the component by force after selecting the appropriate item from the menu screen.
Do not operate the system by force with selecting the “ PREFILLING + HEATING ” option if no repair for the
fuel line relating components has been done.
This means the fuel is in the fuel line.If an excessive fuel is supplied, it may cause smoke and abnormal
"Banging" noise when the fuel is burned.
If the "F2 KEY STOP" is pressed, operation test is stopped.
For self - diagnosis test and sensors outputs during compulsory operation test, press "ESC KEY".
When a self - diagnosis test is completed, disconnect the self - diagnosis connector or press "F2 KEY STOP"
from the "PREFILLING + HEATING" menu to stop the compulsory operation.
In case of selecting the individual part (ex. Combustion air fan, water pump, ), press "ESC KEY" to stop the
test.
In case of selecting the "PREFILLING + HEATING" option, about 2 minutes are required to conduct cleaning
process after pressing the "F2 KEY STOP".
It is a normal process to burn the fuel left in the fuel line.
6. To conduct self diagnosis test, press "ESC" and then "01. DIAGNOSTIC TROUBLE CODES" option.
7.Select "02. CURRENT DATA" to view the current status of the components.