brake KIA CARNIVAL 2007 Manual PDF

[RHD]
3.Fill the brake reservoir with the brake fluid and bleed the brake system (Refer to 'Bleeding of brake system').
DISASSEMBLY
1.Remove the reservoir cap and drain the brake fluid into a suitable container.
2. Remove the fluid level sensor.
3. Remove the reservoir from the master cylinder, after remove mounting screw (A).
[LHD]
4.Remove the retainer ring (A) by using the snap ring pliers.

5.Remove the primary piston assembly (A).
6. Remove the pin (C) with the secondary piston (B) pushed completely using a screwdriver. Remove the secondary
piston assembly (B).
Do not disassemble the primary and secondary piston assembly.
INSPECTION
1.Check the master cylinder bore for rust or scratching.
2. Check the master cylinder for wear or damage. If necessary, clean or replace the cylinder.
a.If the cylinder bore is damaged, replace the master cylinder assembly.
b. Wash the contaminated parts in alcohol.
REASSEMBLY
1.Apply genuine brake fluid to the rubber parts of the cylinder kit and grommets.
2. Carefully insert the springs and pistons in the proper direction.
3. Press the piston with a screwdriver (A) and install the cylinder pin (B).

Brake Line

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the brake hose clip (A).
2.Loosen the brake tube (A) nut holding the brake hose (B) nut with a wrench.
3.Remove the brake hose (B).
4. Remove the brake hose connecting bolt (A) from the caliper assembly.
INSTALLATION
1.Install the brake hose (A) connecting bolt (B) and washer (C).

2.Tighten the brake tube (A) nut holding the brake hose (B) nut with a wrench.
3.Install the brake hose clip (A).
4.After installation, breed the air in the brake system.
Be careful not to damage the brake hose by sharp edges or tools.
INSPECTION
a.Check the brake tubes for cracks, crimps and corrosion.
b. Check the brake hoses for cracks, damaged and oil leakage.
c. Check the brake tube flare nuts for damage and oil leakage.
INSPECTION
a.Check the brake tubes for cracks, crimps and corrosion.
b. Check the brake hoses for cracks, damaged and oil leakage.
c. Check the brake tube flare nuts for damage and oil leakage.

Brake Pedal

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the lower crash pad. (Refer to BD group 'Crash pad')
2. Remove the brake switch connector.
3. Remove the trans cable (A) in case of the adjustable brake pedal.
4.Remove the mounting bolt(A) of the peal position sensor connector in case of the adjustable brake pedal.
5.Remove the snap pin connecting the booster.
6. Remove the hinge shaft connecting the pedal tray.
7. Remove the brake pedal.
INSTALLATION
1.Installation is the reverse of removal.
Coat the inner surface of the bushings with the specified grease.
Specified grease : Lig- 2
2. Before inserting the pin, apply the specified grease to the clevis pin.

3.Install the snap pin.
4. Adjust the brake pedal height and free play.
Before connecting trans cable, be sure that position of pivot pin (A) is initializen.
5.Install the stop lamp switch.
INSPECTION
1.Check the bushing for wear.
2. Check the brake pedal for bending or twisting.
3. Check the brake pedal return spring for damage.
4. Check the stop lamp switch.
(1) Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when
the plunger of the stop lamp switch is pushed in and when it is released.
(2) The stop lamp switch is in good condition if there is no continuity when plunger(A) is pushed.

Front Disc Brake

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.