engine KIA CARNIVAL 2007 Repair Manual

THERMOSTAT
1.Immerse the thermostat in water and gradually heat water.
2.Check the valve opening temperature.
Valve opening temperature : 82°C (177°F)
Full opening temperature : 95°C (205°F)
If the valve opening temperature is not as specified, replace the thermostat.
3. Check the valve lift.
Valve lift : Min. 10mm (0.4in.) at 95°C (205°F)
If the valve lift is not as specified, replace the thermostat.
ENGINE COOLANT REFILLING AND BLEEDING
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high
pressure escaping from the radiator.
When pouring engine coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or
the paint. If any coolant spills, rinse it off immediately.
1. Make sure the engine and radiator are cool to the touch.
2. Open the radiator cap.
3. Loosen the drain plug, and drain the coolant.
4. Tighten the radiator drain plug securely.
5. Remove, drain and clean the reservoir tank.
6. Fill water slowly through the radiator cap. Push the upper/lower hoses of the radiator so as to bleed air easily.
7. Warm the engine until the cooling fan operates 2~3 times.
Accelerate the engine 2~3 times without load.
8. Wait until the engine is cold.
9. Repeat the steps 1~8 until the water drained is clean.
10. Fill fluid mixture with coolant and water(4 : 6) slowly through the radiator cap. Push the upper/lower hoses of the
radiator so as to bleed air easily.
11. Start the engine and run so coolant circulates.
When the cooling fan operates and coolant circulates, refill coolant through the radiator cap.
12. Repeat 11 until the cooling fan cycles 3 ~ 5 times and bleed air sufficiently out of the cooling system.

13.Install the radiator cap and fill the reservoir tank to the "MAX"(or "F") line with coolant.
14. Run the vehicle under idle until the cooling fan operates 2 ~ 3 times.
15. Stop the engine and wait until coolant gets cool.
16. Repeat 10 to 15 until the coolant level doesn't fall any more, bleeding air out of the cooling system.
Check the coolant level again in the reservoir tank for 2 ~ 3 days after replacing coolant.
CAP TESTING
1.Remove the radiator cap, wet its seal with engine coolant, and install it to a pressure tester.
2.Apply a pressure of 93 ~ 123kPa (0.95 ~ 1.25kgf/cm², 14 ~ 19psi).
3. Check for a drop in pressure.
4. If the pressure drops, replace the cap.

2007 > 2.7L V6 GASOLINE >
REMOVAL
Oil pump case
1. Drain engine oil.
2. Remove the front right wheel and tire.
3. Remove the front right side cover.
4. Remove the front muffler.
5. Remove the generator.
6. Remove the timing belt.
7. Remove the oil filter bracket(A).
8.Using SST(09215- 3C000), remove the lower oil pan(A).
Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
9. Remove the oil screen(A).

10.Remove the upper oil pan, using the SST(09215- 3C000)(A).
Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
11. Remove the oil pump case(A).
12.After removing the plug(A), remove the relief spring(B) and the velief plunger(C).
REPLACEMENT
OIL AND FILTER
a.Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading
to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants
which may cause skin cancer.
b. Wear protective clothing and gloves in order to minimize the length and frequency of contact of your skin to
used oil. Wash your skin thoroughly with soap and water, or use water- less hand cleaner, to remove any used
engine oil. Do not use gasoline, thinners, or solvents.

c.In order to preserve environment, used oil or used oil filter must be disposed only at designated disposal
sites.
1. Park the car on a level ground.
Start the engine and let it warm up.
2. Turn the engine off.
3. Drain engine oil.
(1) Remove the oil filler cap.
(2) After lifting the car, remove the oil drain plug(A) and drain oil into a container.
4. Replace the oil filter.
(1) Remove the oil filter(B).
(2)Check the part number of a new oil filter is as the same as that of the old one.
(3) Replace the oil filter.
(4) Tighten it slightly until the o - ring of the filter cap contacting on its position.
(5) Tighten it with the specified torque.
Tightening torque
16.7 ~ 24.5Nm(1.7 ~ 2.5kgf.m, 12.3 ~ 18.1lb- ft)
5. Refill with engine oil.
(1) Install the oil drain plug with a new gasket.
Tightening torque
34.3 ~ 44.1Nm (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb- ft)
(2) Fill with fresh engine oil, after removing the engine oil level gauge.
Capacity
Total : 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil pan : 4.2 L (4.43 US qt, 3.69 lmp qt)
Drain and refill including oil filter : 4.5 L (4.75 US qt, 3.95 lmp qt)
Oil quality : ABOVE API SJ / SL or SAE 5W- 20
(3) Install the oil filler cap and the oil level gauge.
6. Start the engine and ensure that no oil is leaking from the drain plug or the oil filter.
7. Recheck engine oil level.
INSTALLATION
Oil pump case
1. Assembly the relief spring(B) and the relief plunger(C) and tighten the plug(A).

Tightening torque
39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb- ft)
2.Install oil pump case.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm(0.0984in.)
a.Make clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not be protrude into the inside of oil pan.
d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
e. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Install the oil pump case(A).
Tightening torque
18.6 ~ 23.5(1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb- ft)

d.To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
e. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
Bolts 1~15 : 18.6 ~ 23.5Nm(1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb- ft)
Bolts 16,17 : 4.9 ~ 6.9Nm(0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb - ft)
5.Install the oil screen.
Tightening torque
14.7 ~ 21.6Nm(1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb- ft)
Always use a new gasket.
6. Install the lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.
The part must be assembled within 5 minutes after the sealant was applied.

a.Make clean the sealing face before assembling two parts.
b. Remove harmful foreign materials on the sealing face before applying sealant.
c. When applying sealant gasket, sealant must not be protrude into the inside of oil pan.
d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
e. After assembly, wait at least 30 minutes before filling the engine with oil.
(3) Fix the oil pan and tighten the bolts in several steps uniformly.
Tightening torque
9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb - ft)
7.Install the oil filter bracket(A).
Tightening torque
18.6 ~ 23.5Nm(1.9 ~ 2.4kgf.m, 13.7~ 17.4lb- ft)

Always use a new O - ring.
8. Install the timing belt, the generator and the front muffler.
9. Install the front right side cover and the wheel and tire.
10. Fill with engine coolant.
11. Start engine and check for leaks.
12. Recheck engine coolant level.
INSPECTION
1.Check engine oil quality.
Check the oil for deterioration, entry of water, discoloring or thinning.
If the quality is visibly poor, replace oil.
2. Check the engine oil level.
After warning up the engine, make the engine stand still for five minutes or more. The oil level should be between
the 'L' and 'F' marks on the dipstick, then.
If low, check for leakage and add oil up to the "F" mark.
Do not fill with engine oil above the "F" mark.
SELECTION OF ENGINE OIL
Recommended API classification : Above SJ or SL
Recommended SAE viscosity grades : 5W- 20

For best performance and maximum protection of all types of operation, select only those lubricants which :a. Satisfy the requirement of the API classification.
b. Have proper SAE grade number for expected ambient temperature range.
Lubricants that do not have both an SAE grade number and API service classification on the container should
not be used.
RELIEF SPRING
1.Check the relief plunger.
Apply engine oil on the plunger and check that it moves smoothly in the hole. If it does not, replace the plunger or
the front case only in necessary cases.
2. Check the relief valve spring.
Check deformation or damage of the relief valve spring.
Specification
Free length : 43.8mm(1.7244in.)
Load : 36.3N(3.7kg, 8.21b)±3.9N(0.4kg, 0.9lb) / 40.1mm(1.5787in.)
OIL PRESSURE SWITCH
1.Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.