engine KIA CARNIVAL 2007 Repair Manual

2007 > 2.7L V6 GASOLINE >
REMOVAL
INTAKE MANIFOLD ASSEMBLY
1. Remove the engine cover.
2. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the MAF connector(A).
(2) Disconnect the breather hose(B) from air cleaner hose.
(3) Remove the intake air hose and air cleaner assembly(C).
3.Disconnect the engine wiring harness connectors.
(1) Disconnect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil
harness(D) and the No.1 VIS(Variable Induction System) connector(E).
(2)Disconnect the bank 1 front/rear O2 sensor connectors(A).
(3)Disconnect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition
coil connectors(F).

(7)Disconnect the bank 2 CMP sensor connector(A) and the ECT(Engine Coolant Temperature) sensor
connector(B).
(8)Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C).
(9)Disconnect the bank 1 CMP sensor connector(A).
4.Remove the PCV(Pulge Control Valve) hose(A).

1.Install the intake manifold assembly with a new gasket to a cylinder head assembly. Tighten the bolts in two steps.
Tightening torque
Step 1(a~h): 3.9~5.9Nm(0.4~0.6kgf.m, 2.9~4.3lb- ft)
Step 2(1~8): 18.6~23.5Nm(1.9~2.4kgf.m, 13.7~17.4lb - ft)
When installing the gasket on the cylinder head, check the indentification marks(LH/RH) not to be installed
wrong.
2. Install the delivery pipe.
3. Connect the LH injector connector.
4. Install the surge tank.
Tightening torque
18.6~23.5Nm(1.9~2.4kgf.m, 13.7~17.4lb - ft)
5. Install the surge tank mounting bracket.
Tightening torque
18.6~23.5Nm(1.9~2.4kgf.m, 13.7~17.4lb - ft)
6. Install the ETC(Electronic Throttle Control) system fixing bracket.
7. Connect the hoses and connectors.
8. Install the air cleaner assembly.
9. Install the engine cover.
EXHAUST MANIFOLD ASSEMBLY
1.Install the exhaust manifold assembly with a new gasket.
Tightening torque
29.4~34.3Nm(3.0~3.5kgf.m, 21.7~25.3lb - ft)
2. Install the heat protector.
Tightening torque
16.7~21.6Nm(1.7~2.2kgf.m, 12.3~15.9lb - ft)
3. Install the front muffler assembly.

CHAPTER 3:
Engine Electrical System

2.After pressing ENTER key, start the engine.
3.Cranking voltage and starter test results will be displayed on the screen.
Take a relevant action according to the test results by referring to the starter test results as given below.
4.To continue charging system test, press ENTER.
STARTER TEST RESULTS
RESULT ON PRINTER REMEDY
Cranking voltage normal System shows a normal starter draw
Cranking voltage low Cranking voltage is lower than normal level
=> Check starter
Charge battery The state of battery charge is too low to test
=>Charge the battery and
retest
Replace battery => Replace battery
=> If the vehicle is not started though the battery
condition of "Good and fully charged" is displayed.
=> Check wiring for open circuit, battery cable connection,
starter and repair or replace as necessary.
CHARGING SYSTEM TEST PROCEDURE
1.
Press ENTER to begin charging system test.

2.ENTER button is pressed, the tester displays the actual voltage of generator.
Press ENTER to test the charging system.
3.The MICRO 570 will prompt you to rev the engine until the rev detected. It will then collect the data.
4.Press ENTER.
5.The MICRO 570 will analyze the charging system output at idle for comparison to other readings.

6.The MICRO 570 will detect the amount of ripple from the charging system to the battery. Excessive ripple usually
means the stator is damaged or that one or more generator diodes have failed.
7.The MICRO 570 will prompt you to turn on accessary loads. It will then test at idle and prompt you to rev the
engine. The analyzer will determine if the charging system can provide enough current for the demands of the
vehicle's electrical system.
When asked to turn of the accessory loads, turn of the blower to high(heater), the high beam beadlights, and
rear defogger. DO NOT use cyclical loads such as air conditioning or wind- shield wipers.
8. After the test, the MICRO 570 will display the idle voltage, load voltage and the state results.

2007 > 2.7L V6 GASOLINE >
TROUBLE SHOOTING
IGNITION SYSTEM
Symptom Suspect area Remedy
Engine will not start or
is hard to start
(Cranks OK) Ignition lock switch
Inspect ignition lock switch, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Spark plugs Inspect spark plugs, or replace as required
Ignition wiring disconnected or broken Repair wiring, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Engine hesitates/poor
acceleration Spark plugs and spark plug cables
Inspect spark plugs / cable, or replace as required
Ignition wiring Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or replace as required
CHARGING SYSTEM Symptom Suspect area Remedy
Charging warning
indicator does not
light with ignition
switch "ON" and
engine off. Fuse blown
Check fuses
Light burned out Replace light
Wiring connection loose Tighten loose connection
Electronic voltage regulator Replace voltage regulator
Charging warning
indicator does not go
out with engine
running. (Battery
requires frequent
recharging) Drive belt loose or worn
Adjust belt tension or replace belt
Battery cable loose, corroded or worn Inspect cable connection, repair or replace
cable
Electronic voltage regulator or alternator Replace voltage regulator or alternator
Wiring Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short circuit Inspect wiring connection, repair or replace
wiring
Electronic voltage regulator or alternator Replace voltage regulator or alternator
Poor grounding Inspect ground or repair
Worn battery Replace battery
STARTING SYSTEM Symptom Suspect area Remedy
Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or
worn out Repair or replace cables
Transaxle range switch (Vehicle with
automatic transaxle only) Refer to TR group - automatic transaxle

Fuse blownReplace fuse
Starter motor faulty Replace
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or
worn out Repair or replace cables
Starter motor faulty Replace
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but engine will not
crank Short in wiring
Repair wiring
Pinion gear teeth broken or starter
motor Replace
Ring gear teeth broken Replace fly wheel or torque converter

2007 > 2.7L V6 GASOLINE >
DESCRITION
Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data
for the engine operating conditions are preprogrammed in the memory of the ECM (Engine Control Module).
The engine operating conditions (speed, load, warm- up condition, etc.) are detected by the various sensors. Based on
these sensor signals and the ignition timing data, signals to interrupt the primary current are sent to the ECM. The
ignition coil is activated, and timing is controlled.