brake KIA CARNIVAL 2007 Repair Manual

2007 > 2.7L V6 GASOLINE >
Operation and Leakage Check
Check all of the following items:
Component Procedure
Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not
work properly, check the brake booster. Replace the brake booster as an assembly if it
does not work properly or if there are signs of leakage.
Piston cup and pressure cup
inspection (B) a.
Check brake operation by applying the brakes. Look for damage or signs of fluid
leakage. Replace the master cylinder as an assembly if the pedal does not work
properly or if there is damage or signs of fluid leakage.
b. Check for a difference in brake pedal stroke between quick and slow brake
applications. Replace the master cylinder if there is a difference in pedal stroke.
Brake hoses (C) Look for damage or signs of fluid leakage. Replace the brake hose with a new one if it
is damaged or leaking.
Caliper piston seal and
piston boots (D) Check brake operation by applying the brakes.
Look for damage or signs of fluid leakage. If the pedal does not work properly, the
brakes drag, or there is damage or signs of fluid leakage, disassemble and inspect the
brake caliper. Replace the boots and seals with new ones whenever the brake caliper
is disassembled.
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry out the following tests
1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains
unchanged, thebooster is inoperative.

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]

[RHD]
BRAKE PEDAL BRAKE SWITCH ADJUSTMENT
PEDAL HEIGHT1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until
it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left- side center of
the pedal pad (D).
Standard pedal height( with carpet removed): 192.4 mm(7.57 in.)
3.Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the
floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod
depressed.

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)

a.If the pad thickness is out of specilfication, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.
INSPECTION OF REAR DISC BRAKE PAD
1.Check the rear disc brake pad thickness through the caliper body inspection hole.
Pad thickness
Standard value : 10.0 mm (0.39 in)
Service limit : 2.0 mm (0.0787 in)
a.If the pad thickness is out of specification, left and right pads must be replaced as a complete set.
b. When the thickness difference between the left pad and right pad is large, check the sliding condition of
the piston and the guide rod.

Brake Booster

2007 > 2.7L V6 GASOLINE >
Removal
1.Disconnect the vacuum hose (A) from the brake booster (B).
[LHD]
[RHD]
2.Remove the master cylinder (Refer to 'Master cylinder removal').
3. Remove the snap pin (A) and clevis pin (B).
4.Remove the four booster mounting nuts (C).
5. Remove the brake booster (A).

3.Connect the booster push rod and brake pedal with a pin (B) and install a snap clevis pin (A) to the clevis pin (B).
Grease the pin before installing the snap pin.
Always use a new snap pin.
4. Install the master cylinder.
5. Connect the vacuum hose to the brake booster.
6. After filling the brake reservoir with brake fluid, bleed the system (Refer to 'Bleeding of brake system',).
7. Check for fluid leakage.
8. Check and adjust the brake pedal for proper operation.

2007 > 2.7L V6 GASOLINE >
REMOVAL
Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off
immediately with water.
1. Remove air cleaner mounting bolts (B) from the air cleaner mounting bracket and air cleaner body (A).(LHD)
2.Remove the air cleaner assembly (A) by removing the air cleaner mounting bolt (B) from the bracket.(LHD)
3.Remove the surge tank.(Refer to EM Gr.)
(RHD- GSL 3.8)
4. Disconnect the brake fluid level switch connector (A), and remove the reservoir cap (B).
[LHD]
[RHD]

5.Remove the brake fluid from the master cylinder reservoir (C) with a syringe.
6. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop
towels.
7. Remove the master cylinder mounting nuts (B) and washers.
[LHD]
[RHD]
8.Remove the master cylinder(C) from the brake booster. Be careful not to bend or damage the brake lines when
removing the master cylinder.
INSTALLATION
1.Install the master cylinder on the brake booster with 2 nuts.
2. Connect the two brake tubes and the brake fluid level sensor connector.
[LHD]