air bleeding KIA CARNIVAL 2007 Workshop 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.

CHECKING POWER STEERING BELT TENSION
Refer to EM group(Timing system).
CHECKING POWER STEERING FLUID LEVEL
1.Position the vehicle on a level surface.
2. Start the engine. With the vehicle kept stationary, turn the steering wheel several times continuously to raise the
fluid temperature to 50- 60°C (122 - 140°F).
3. With the engine at idle, turn the steering wheel fully clockwise and counter- clockwise several times.
4. Make sure that there is no foaming or cloudiness in the reservoir fluid.
5. Stop the engine and check for any difference in fluid level between a stationary and a running engine.
a.If the fluid level varies 5 mm (0.2 in) or more, bleed the system again.
b. If the fluid level suddenly rises after stopping the engine, further bleeding is required.
c. Incomplete bleeding will produce a chattering sound in the pump and noise in the flow control valve, and
lead to decreased durability of the pump.
REPLACING POWER STEERING FLUID
1.Jack up the front wheels and support them with jackstands.
2. Disconnect the return hose from the oil reservoir and plug the oil reservoir.
3. Connect a vinyl hose to the disconnected return hose, and drain the oil into a container.
4. Remove the fuel pump fuse, then start the engine and wait for the engine to stall. Next, while operating the starting
motor intermittently, turn the steering wheel all the way to the left and then to the right several times to drain the
fluid.
5. Connect the return hoses, then fill the oil reservoir with the specified fluid.
6. Reinstall the fuel pump fuse.
7. Start the engine. Check for oil leakage.
8. Stop the engine.
9. Bleed the system.
Power steering fluid type : PSF - 3
Total quantity : Approx 1.1 liter
AIR BLEEDING
1.Remove the fuel pump fuse, then start the engine and wait for the engine to stall. Next, while operating the starting
motor intermittently (for 15 ~ 20 seconds), turn the steering wheel all the way to the left and then to the right five or
six times.

a.During air bleeding, replenish the fluid supply so that the level never falls below the lower position of the
filter.
b. If air bleeding is done while the vehicle is idling, the air will be broken up and absorbed into the fluid. Be
sure to do the bleeding only while cranking.
c. Reinstall the fuel pump fuse, and start the engine(idling).
d. Turn the steering wheel to the left and the right until there are no air bubbles in the oil reservoir.
Do not hold the steering wheel turned all the way to either side for more than ten seconds.
e. Confirm that the fluid is not milky, and that the level is up to the position specified on the level gauge.
f. Confirm that there is little change in the surface o the fluid when the steering wheel is turned left and right.
a. If the surface of the fluid changes considerably, air bleeding should be done again.
b. If the fluid level rises suddenly when the engine is stopped, it indicates that there is still air in the
system.
c. If there is air in the system, a jingling noise may be heard from the pump and the control valve
may also produce unusual noises. Air in the system will shorten the life of the pump and other
parts.
OIL PUMP PRESSURE TEST (OIL PUMP RELIEF PRESSURE)
1.Disconnect the pressure hose from the oil pump. Connect the special tool between the oil pump and pressure hose
as illustrated.
2. Bleed the air, and then start the engine and turn the steering wheel several times so that the fluid temperature
rises to approximately 50°C (122°F).
3. Set the engine speed to 1,000 rpm.
4. Close the shut- off valve of the special tool and measure the fluid pressure to confirm that it is within the range.
standard vaule :
Relief pressure: 90 +3/- 2 kgf/cm²
Don’t keep the shut- off valve on the pressure gauge closed for longer than seconds.

14.Remove the power steering gear box (A) from the sub- frame by loosening the mounting bolts.
Tightening torque Nm (kgf.m, lb - ft):
60 ~ 80 (6.0 ~ 8.0, 43~58)
INSTALLATION
Be sure to connect between a tube and a hose as shown in the illustration.
1.Installation is the reverse of removal.
2. After installation, bleed the power steering system. (Refer to the air bleeding in ST group)
3. Adjust the wheel alignment. (Refer to SS group)
DISASSEMBLY
1.Remove the tie rod end (B) from the tie rod (A).

6.Remove the under cover and then loosen the oil cooler tube bracket bolts. (Refer to BD - group)
Be sure to connect between a tube and a hose as shown in the illustration.
7.Installation is reverse of the removal.
8. After installation, bleed the power steering system. (Refer to the air bleeding in ST group)

The pressure tube does not twist and come in contact with other components.
2. Add power steering fluid
3. Bleed the power steering system. (Refer to the air bleeding in ST group)
4. Check the oil pump pressure.
DISASSEMBLY
1.Remove two bolts from the oil pump body (A), and then remove the suction pipe (B) and O - ring.
2.Loosen the four bolts and remove the oil pump cover assembly (A) and the gasket.
3.Remove the rotor and vanes.

2007 > 2.7L V6 GASOLINE >
DESCRIPTION
This specification applies to HCU(Hydraulic Control Unit) and ECU(Electronic Control Unit) of the HECU.(Hydraulic and
Electronic Control Unit)
This specification is for the wiring design and installation of ABS/TCS/ESC ECU.
This unit has the functions as follows.
a. Input of signal from Pressure sensor, Steering angle sensor, Yaw & Lateral G sensor, the wheel speed sensors
attached to each wheel.
b. Control of braking force / traction force/ yaw moment.
c. Failsafe function.
d. Self diagnosis function.
e. Interface with the external diagnosis tester.
Installation position : engine compartment a. Brake tube length from Master cylinder port to HECU inlet port should be max. 1m
b. The position should not be close to the engine block and not lower than the wheel.
OPERATION
The ECU shall be put into operation by switching on the operating voltage (IGN).
On completion of the initialization phase, the ECU shall be ready for operation.
In the operating condition, the ECU shall be ready, within the specified limits (voltage and temperature), to process the
signals offered by the various sensors and switches in accordance with the control algorithm defined by the software
and to control the hydraulic and electrical actuators.
Wheel Sensor signal processing
The ECU shall receive wheel speed signal from the four active wheel sensors.
The wheel signals are converted to voltage signal by the signal conditioning circuit after receiving current signal from
active wheel sensors and given as input to the MCU.
Solenoid Valve Control
When one side of the valve coil is connected to the positive voltage that is provided through the valve relay and the
other side is connected to the ground by the semiconductor circuit, the solenoid valve goes into operation.
The electrical function of the coils are always monitored by the valve test pulse under normal operation conditions.
Voltage limits
a.Overvoltage
When overvoltage is detected(above 16.8 V), the ECU switches off the valve relay and shuts down the system.
When voltage is returned to operating range, the system goes back to the normal condition after the initialization
phase.
b. Undervoltage
In the event of undervoltage(below 9.3 V), ABS control shall be inhibited and the warning lamp shall be turned on.
When voltage is returned to operating range, the warning lamp is switched off and ECU returns to normal operating
mode.
Pump Motor Checking
The ECU performs a pump motor test at a speed of 15km/h once after IGN is switched on.
Diagnostic Interface
Failures detected by the ECU are encoded on the ECU, stored in a EEPROM and read out by diagnostic equipment
when the ignition switch is turned on.
The diagnosis interface can also be used for testing the ECU during production of the ECU and for actuating the HCU
(Air - bleeding line or Roll and Brake Test line).
Warning Lamp module

CHECK FOR BLOWN FUSE
Check continuity of fuse (10A) from the engine compartment junction block.
Is there continuity?
▶ Repair an open in the wire between ABS fuse and 1 of cluster connector.
▶ Replace the blown fuse.
DETECTING CONDITION
Trouble Symptoms Possible Cause
If the HECU detects trouble, it lights the ABS warning lamp while at
the same time prohibiting ABS control. At this time, the HECU
records a DTC in memory.Even though the normal code is output, the
ABS warning lamp remains ON, then the cause may be probably an
open or short in the ABS warning lamp circuit. a.
An open in the wire
b. Inoperative instrument cluster assembly
c. Inoperative ABS warning lamp module
d. Inoperative HECU
INSPECTION PROCEDURES
CHECK DTC OUTPUT.
1. Connect the Scan Tool to the 16P data link connector located behind the driver's side kick panel.
2. Check the DTC output using Scan Tool.
Is DTC output ?
▶ Repair circuit indicated by code output.
▶ Check instrument cluster.
CHECK INSTRUMENT CLUSTER
Disconnect the cluster connector and turn the ignition switch ON.
Does the ABS warning lamp remains ON?
▶ Replace the instrument cluster.
▶ Check for open the wire.
CHECK FOR OPEN IN THE WIRE
Check for continuity in the wire between cluster and ABS control module.
Is there continuity?
▶ Replace the ABS control module and recheck.
▶ Repair an open in the wire between cluster and ABS control module.
BLEEDING OF BRAKE SYSTEM
1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
If there is any brake fluid on any painted surface, wash it off immediately.

When pressure bleeding, do not depress the brake pedal.
Recommended fluid........ DOT3 or DOT4
2. Connect a clear plastic tube to the brake caliper bleeder plug and insert the other end of the tube into a half filled
clear plastic bottle.
3.Connect the scan tool to the data link connector located underneath the dash panel.
4.Select and operate according to the instructions on the scan tool screen.
You must obey the maximum operating time of the ABS motor with the scan tool to prevent the motor pump
from burning.
(1) Select kia vehicle diagnosis.
(2) Select vehicle name.
(3) Select Anti- Lock Brake system.
(4) Select air bleeding mode.
(5) Press "YES" to operate motor pump and solenoid valve.