service KIA CARNIVAL 2007 User Guide

DCC Solenoid valveShort to B+
P0743P0743
Open or short to ground
1st speed asynchronous Synchronous error
0,11P0731
P0731
2nd speed asynchronous Synchronous error P0732P0732
3rd speed asynchronous Synchronous error P0733P0733
4th speed asynchronous Synchronous error P0734P0734
Reverse speed asynchronous Synchronous error ――
CAN No ID from ECM
2,3,6,7,9,10,11―
P1604
CAN BUS off ―P1603
Damper clutch Abnormal system 7P0741P0741
A/T relay Short to ground or open 0,11P0885P0885
Inhibitor switch Short to ground or open
―P0707
P0707
Short to B+ or short between switches P0708P0708
VFS Short to B+
11
―P0748
Short to ground 0,11
Open 11
CKP sensor Sensor errorNe=3,000rpm
7,9 ―
―
TPS sensor Sensor errorTPS=50Ë――
SERVICE DATA LIST(WITH SCAN TOOL)
No.ITEM NAME UNITDATA Data Description Failure
1 ENGINE RPM rpm700 rpmCurrent Engine rpm 0 rpm
2 VEHICLE SPEED km/h0km/hCurrent Vehicle speed 0km/h
3 THROTTLE
P.SENSOR %
12.5%Current TPS open angle 0%
4 INPUT SPEED(PG - A) rpm700 rpmInput speed rpm. Always output rpm
when turning start ON 0 rpm
5 OUTPUT SPEED(PG -
B) rpm
0 rpmOutput speed rpm. Always output
rpm when driving 0 rpm
6 DCC(TCC) SOLENOID
DUTY %
0%Control 0%
→ 100% when
operating Damper Clutch
7 DAMPER CLUTCH
SLIP rpm
260 rpmCurrent Damper clutch slip ratio 0 rpm
8 LR SOLENOID DUTY %100%Control 100%
→ 0% when
operating brake 0%
9 UD SOLENOID DUTY %100%Control 100%
→ 0% when
operating clutch 0%
10 2ND SOLENOID DUTY %100%Control 100%
→ 0% when
operating clutch 0%
11 OD SOLENOID DUTY %100%Control 100%
→ 0% when
operating clutch 0%
12 VFS SOLENOID DUTY Ë0~400Ë ―

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.

25.Install the air cleaner assembly (B) by tightening the two mounting bolts (A).
26.Reassemble the air cleaner filter, install the air cleaner upper body (B) and connect the air flow sensor connector
(A).
27.Install the battery (A).
28.Refill the transaxle fluid. (see 'Service adjustment procedure')
29. Refill the power steering fluid. (see 'ST' group)

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)

2007 > 2.7L V6 GASOLINE >
SPECIAL SERVICE TOOLS
Tool (Number and Name) IllustrationUse
09568 - 4A000
Ball joint remover
Removal of Ball joint
(Front upper arm/lower arm, & Rear
upper arm)
09532 - 11600
Preload socket
Measurement of the front lower arm
ball joint starting torque.
(Use with torque wrench)
09546 - 26000
Strut spring compressor
Compression of the coil spring
09214 - 32000
Mount bushing remover and installer
Removal & installation of lower arm
bushing(G)
(Use with 09216 - 21100)
09216 - 21100
Mount bushing remover and installer
Removal & installation of lower arm
bushing(G)
(Use with 09216 - 32000)
09216 - 21600
Mount bushing remover and installer
arbor
Removal and installation of trailing
arm bushing
(Use with 09552 - 38100)
09552 - 38100 Removal and installation of the rear

2007 > 2.7L V6 GASOLINE >
SERVICE ADJUSTMENT PROCEDURE
CHECKING STEERING WHEEL FREE PLAY
1. Start the engine and with the steering wheel in the straight ahead position.
2. Measure the play while turning the steering wheel to the left and right.
Standard value :
Steering wheel free play : 30 mm (1.1 in)
3.If the play exceeds the standard value, inspect the connection between the steering shaft and tie rod ends.
CHECKING STEERING ANGLE
1.Place the front wheel on a turning radius gauge and measure the steering angle.
Standard value
VRS on Inner
38.64 °
Outer 31.78 °
VRS off Inner
41.91 °
Outer 33.54 °
2. If the measured value is not within the standard value, adjust the toe and inspect again.
CHECKING THE TIE ROD END BALL JOINT STARTING TORQUE
1.Disconnect tie rod and knuckle with the special tool (09568- 4A000).

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Items Specifications
Steering column/ shaft Type
Tilt
Tilt stroke +7°/ - 11.7°
Steering gear Type
Rack & pinion
Rack stroke VRS On
148 mm (5.827 in)
VRS Off 156 mm (6.142 in)
Power steering pump Type
Vane
Diesel Relief pressure
90 kgf/cm²
Discharge 9.6 cc/rev
Gasoline Relief pressure
90 kgf/cm²
Discharge 10.5 cc/rev
SERVICE STANDARD
Items Specifications
Steering wheel free play 30 mm (1.12 in)
Steering angle VRS on
Inner
38.64°
Outer 31.78°
VRS off Inner
41.91°
Outer 33.54°
TIGHTENING TORQUE
Items NmKgf.m Lb- ft
Steering wheel lock nut 40 ~ 504.0 ~ 5.0 29 ~ 36
Steering column mounting bolts and nut 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Bolt connecting steering column to universal
joint 15 ~ 20
1.5 ~ 2.010.8 ~ 14.5
Bolt connecting universal joint to steering gear 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Steering column mounting bolts and nut 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Tie rod end castle nut 35 ~ 453.5 ~ 4.5 25 ~ 33
Front lower arm ball joint assembly bolts 90 ~ 1209.0 ~ 12.0 65 ~ 87
Stabilizer link to strut assembly nut 100 ~ 12010.0 ~ 12.0 72 ~ 87
Rear roll stopper to sub- frame bolts 50 ~ 605.0 ~ 6.0 36 ~ 43
Pressure tube to valve body housing nut 12 ~ 181.2 ~ 1.8 9 ~ 13
Pressure tube to oil pump eye bolt 65 ~ 756.5 ~ 7.5 47 ~ 54
Return tube to valve body housing nut 12 ~ 181.2 ~ 1.8 9 ~ 13
Power steering gear box to sub- frame bots 90 ~ 1109.0 ~ 11.0 65 ~ 80
LUBRICANT
Item Lubricant Quantity
Power steering fluid PSF - 31.1 L

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

FLANGE WITH GUIDE PIN
Check the new O - ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to
specified torque.
Size Tightening torque [ N.m (kg.m, lbf.ft) ]
General bolt, nut
4T 7T
M6 5 - 6(0.5 - 0.6, 3.6 - 4.3) 9 - 11(0.9 - 1.1, 6.5 - 7.9)a
M8 12- 14(1.2 - 1.4, 8.7 - 10) 20 - 26 (2.0 - 2.6, 14 - 18)
M10 25 - 28 (2.5 - 2.8, 18 - 20) 45 - 55 (4.5 - 5.5, 32 - 39)
Size Flange bolt, nut
4T 7T
M6 5 - 7(0.5 - 0.7, 3.6 - 5.0) 8 - 12(0.8 - 1.2, 5.8 - 8.6)
M8 10- 15(1.0 - 1.5, 7 - 10) 19 - 28 (1.9 - 2.8, 14 - 20)
M10 21 - 31 (2.1 - 3.1, 15 - 22) 39 - 60 (3.9 - 6.0, 28 - 43)
HANDLING TUBING AND FITTINGS
The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture- free
refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and
cause problems or serious damage.
THE FOLLOWING PRECAUTIONS MUST BE OBSERVED
1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so
the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean
and dry.