light KIA CARNIVAL 2007 Service Manual

2007 > 2.7L V6 GASOLINE >
removal
1.Disconnect the battery negative cable and wait for at least 3 minutes before beginning work.
2. Remove the following parts. (Refer to BD group)
a. Interior trim
b. Headlining
3. Disconnect the Curtain Airbag harness connector (front & rear).
4.After loosening the mounting bolts (13EA), remove the curtain airbag.
INSTALLATION
a.Be sure to install the harness wires not to be pinched or interfered with other parts.
1. Disconnect the negative ( - ) cable from battery and wait for at least three minutes.
2. Remove ignition key from the vehicle.
3. Install a Curtain Airbag (CAB) on the mounting bracket.
4. Tighten the CAB mounting bolts (13EA).
Tightening Torque (CAB Mounting Bolt)
: 1.9 ~ 2.7 kgf.m(18.6 ~ 26.5 Nm, 13.7 ~ 19.5 lb.ft)
a.Never twist the airbag module when installing it. If the module is twisted, airbag module may operate
abnormally.
5. Connect the CAB connector (front & rear).
6. Reconnect the battery negative cable.
7. After installing the Curtain Airbag (CAB), confirm proper system operation:
a. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.

4.Install the new seatback cover.(Refer to BD group)
5. Install the seat assembly, then connect the Side Airbag (SAB) harness connector.
6. Recline and slide the front seat forward fully, make sure the harness wires are not pinched or interfering with other
parts.
7. Reconnect the battery negative cable.
8. After installing the Side Airbag (SAB), confirm proper system operation:
a. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
2. Remove the door scuff trim. (Refer to BD group)
3. Remove the center pillar trim. (Refer to BD group)
4. Remove the lower anchor bolt.
5. Remove the upper anchor bolt.
6. Loosen the Seat Belt Pretensioner mounting bolts and remove the Seat Belt Pretensioner.
7.Disconnect the Seat Belt Pretensioner connector.
INSTALLATION
1.Disconnect the negative ( - ) cable from battery and wait for at least three minutes.
2. Remove ignition key from the vehicle.
3. Connect the Seat Belt Pretensioner connector.
4. Install the Seat Belt Pretensioner (BPT) with bolts.
Tightening Torque (Seat Belt Anchor Bolt)
: 4.0 ~ 5.5 kgf.m (39.2 ~ 53.9 Nm, 28.9 ~ 39.8 lb.ft)
5. Install the upper and lower anchor bolts.
Tightening Torque (Seat Belt Anchor Bolt)
: 4.0 ~ 5.5 kgf.m (39.2 ~ 53.9 Nm, 28.9 ~ 39.8 lb.ft)
6. Install the center pillar trim and door scuff trim.
7. Reconnect the negative battery cable.
8. After installing the Seat Belt Pretensioner (BPT), confirm proper system operation:
a. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Disconnect the battery negative cable, and wait for at least three minutes before beginning work.
2. Remove the front seat assembly. (Refer to BD group)
3. Loosen the Seat Belt Buckle Pretensioner mounting bolt and remove the Seat Belt Buckle Pretensioner.
INSTALLATION
1.Disconnect the battery negative cable and wait for at least three minutes.
2. Remove the ignition key from the vehicle.
3. Install the Seat Belt Buckle Pretensioner (BUPT) with the bolt.
Tightening torque
: 4.0 ~ 5.5 kgf.m (39.2 ~ 53.9 Nm, 28.9 ~ 39.8 lb.ft)
4. Install the front seat assembly.
a.Ensure that the harness is installed and routed properly to prevent damage to the wiring.
5. Reconnect the battery negative cable.
6. After installing the Seat Belt Buckle Pretensioner (BUPT), confirm proper system operation:
a. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.

2.With the engine stopped, step on the brake pedal several times.
Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good
condition. If there is no change, the booster is inoperative.
3.With the engine running, step on the brake pedal and then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if
the pedal rises, the booster is inoperative.
If the above three tests are okay, the booster performance can be determined as good.
Even if one of the above three tests is not okay, check the check valve, vacuum hose and booster for malfunction.
VACUUM HOSE (CHECK VALVE)
INSPECTION
1. Disconnect the brake booster vacuum hose (check valve built in) (A) at the booster (B).
2. Start the engine and let it idle. There should be vacuum available. If no vacuum is available, the check valve is not
working properly. Replace the back booster vacuum hose and check valve and retest.
[LHD]

BRAKE SWITCH CLEARANCE
Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal arm)
then brake off the switch 3/4 turn to make 0.5 ~ 1.0 mm(0.0197 ~ 0.0394 in.) of clearance between the brake switch
connector. Make sure that the brake lights go off when the pedal is released.
PEDAL FREE PLAY
1.With the engine off, inspect the pedal free play (A) on the pedal pad (B) by pushing the pedal by hand.
Free play: 3 ~ 8 mm (0.12 ~ 0.31 in.)
2.If the pedal free play is out of specification, adjust the brake switch (C). If the pedal free play is insufficient, it may
result in brake drag.
INSPECTION OF FRONT DISC BRAKE PAD
1.Check the brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.5 mm ( 0.41 in)
Service limit : 2 mm (0.0787 in)

2007 > 2.7L V6 GASOLINE >
REMOVAL
Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health.
a. Avoid breathing dust particles.
b. Never use on air hose or brush to clean brake assemblies.
1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove
the front wheels.
2. Remove the guide rod bolt (B), After raise the caliper assembly (A), support it with a wire.
3.Remove pad shim (A), pad retainer (B) and pad assembly (C) in the caliper bracket.
INSTALLATION
1.Install the pad retainers (A) on the caliper bracket.
2.Install pad shims (A) and the brake pads (B) with the wear indicator on the inside.

18Voltage for hybrid ECU 1 A500 mA 60200
5,10,17,19 signal wheel speed sensor FL,
FR, RL,RR
6 mA
16 mA 250200 to
ground 1.5M to bat
16,9,6,8 Voltage supply for the active
wheel speed sensor FL,FR,
RL, RR 6 mA
16 mA 250200 to
ground 1.5M to bat
14,24 wheel speed sensor output
(FR, RL) 20 mA
10 mA 250200
11 Diagnostic wire K 6 mA3 mA 250200
22 ABS - warning lamp actuation 30 mA5 mA 250200
12 EBD- warning lamp actuation 30 mA5 mA 250200
20 brake light switch 10 mA5 mA 250200
15 CAN Low 30 mA20 mA 250200
26 CAN High 30 mA20 mA 250200
ABS HECU CONNECTOR Connector terminal SpecificationCondition
Number Description
1 Ground for recirculation pump Current range: Min.10A
Max.20~39A Always
4 Ground for solenoid valves and
ECU Current range: Min.2.5A
Max.5~15A Always
2 Voltage supply for pump motor
Battery voltageAlways
3 Voltage supply for solenoid valves
16 Voltage supply for the active
wheel speed sensor FL,FR, RL, RR Battery voltage
IG ON
9
6
8
5
signal wheel speed sensor FL, FR, RL,RR Voltage(High) : 0.89~1.26 V
Voltage (Low) : 0.44~0.63 V On driving
10
17
19
11
Diagnostic wire K Voltage (High)
≥ 0.8 * IG ON
Voltage (Low) ≤ 0.2 * IG ON On SCAN TOOL
communication
18 Voltage for hybrid ECU Battery voltageKEY ON/OFF
20 Brake light switch Voltage (High)
≥ 0.8 * IG ON
Voltage (Low) ≤ 0.3 * IG ON BRAKE ON/OFF
SENSOR OUTPUT ON SCAN TOOL(ABS) Description AbbreviationUnitRemarks
1 Vehicle speed sensor VEH. SPDKm/h
2 Battery voltage BATT. VOLV
3 FL Wheel speed sensor FL WHEELKm/h

c.Stop lamp switch circuit.
d. Check the hydraulic circuit for leakage.
Communication with Scan tool is not possible.
(Communication with any system is not possible) a.
Power source circuit
b. Diagnosis line
Communication with Scan tool is not possible.
(Communication with ABS only is not possible) a.
Power source circuit
b. Diagnosis line
c. HECU
When ignition key is turned ON (engine OFF), the ABS
warning lamp does not light up. a.
ABS warning lamp circuit
b. HECU
Even after the engine is started, the ABS warning lamp
remains ON. a.
ABS warning lamp circuit
b. HECU
During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are
due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is
not an abnormality.
DETECTING CONDITION
Trouble Symptoms Possible Cause
Brake operation varies depending on driving conditions and road
surface conditions, so diagnosis can be difficult.However if a normal
DTC is displayed, check the following probable cause. When the
problem is still occurring, replace the ABS control module. a.
Inoperative power source circuit
b. Inoperative wheel speed sensor circuit
c. Inoperative hydraulic circuit for leakage
d. Inoperative HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the Scan Tool with the data link connector and turn the ignition switch ON.
2. Verify that the system is operating to specifications.
Is the system operating to specifications ?
▶ Check the power source circuit.
▶ Erase the DTC and recheck using Scan Tool.
CHECK THE POWER SOURCE CIRCUIT.
1. Disconnect the connector from the ABS control module.
2. Turn the ignition switch ON, measure the voltage between terminal 18 of the ABS control module harness side
connector and body ground.
Specification: approximately B+
Is the voltage within specification?
▶ Check the ground circuit.
▶ Check the harness or connector between the fuse (10A) in the engine compartment junction block and the ABS
control module. Repair if necessary.

DTC is displayed, check the following probable cause. When the
problem is still occurring, replace the ABS control module.b.
Inoperative wheel speed sensor circuit
c. Inoperative hydraulic circuit for leakage
d. Inoperative HECU
INSPECTION PROCEDURES
DTC INSPECTION
1. Connect the Scan Tool with the data link connector and turn the ignition switch ON.
2. Verify that the system is operating to specifications.
Is the system operating to specifications ?
▶ Check the wheel speed sensor circuit.
▶ Erase the DTC and recheck using Scan Tool.
CHECK THE WHEEL SPEED SENSOR CIRCUIT.
Refer to the DTC troubleshooting procedures.
Is the system operating to specifications ?
▶ Check the stop lamp switch circuit.
▶ Repair or replace the wheel speed sensor.
CHECK THE STOP LAMP SWITCH CIRCUIT.
1. Check that stop lamp lights up when brake pedal is depressed and turns off when brake pedal is released.
2. Measure the voltage between terminal 20 of the ABS control module harness side connector and body ground
when brake pedal is depressed.
Specification: approximately B+
Is the voltage within specification?
▶ Check the hydraulic circuit for leakage.
▶ Repair the stop lamp switch. Repair an open in the wire between the ABS control module and the stop lamp
switch.
CHECK THE HYDRAULIC CIRCUIT FOR LEAKAGE.
Refer to the hydraulic lines.
Inspect leakage of the hydraulic lines.
Is the system operating to specifications ?
▶ The problem is still occurring, replace the ABS control module.