boot KIA CARNIVAL 2007 Workshop Manual

2007 > 2.7L V6 GASOLINE >
SPECIAL TOOLS
Tool(Number and name) IllustrationUse
Tie rod end puller
09568 - 4A000
Separation of a lower arm and a tie
rod end ball joint
Front hub remover and installer
09517 - 21500
Removal of a front hub from a
knuckle.
(use with 09517 - 21600)
Main shaft bearing puller
09432 - 11000
Removla of a tone wheel from a
driveshaft
09495 - 3K000
Band installer
Installation of ear type boot band
09495 - 39100
Band installer
Installation of hook type boot band

Gasoline: 50 ~ 65 (5.0 ~ 6.5, 36 ~ 47)
9.Insert pry bar (C) between the transaxle case (B) and driveshaft joint (A), separate driveshaft from the transaxle.
a.Use a pry bar being careful not to damage the transaxle and joint.
b. Do not insert a pry bar too deep, as this may cause damage to the oil seal.
c. Do not pry on the driveshaft by excessive force it may cause components inside the joint kit to dislodge
resulting in a torn boot or a damaged bearing.
10. Pull out the driveshaft from the transaxle case.
a.Plug the hole of the transaxle case with the oil seal cap to prevent contamination.
b. Replace the retainer ring whenever the driveshaft is removed from the transaxle case.
INSTALLATION
a.Replace the circlip with new ones before the installation.
b. Before the installation, apply the gear oil on the driveshaft splines (A) and contacting surface of differential
case oil seal (B).

1.Installation is reverse of the removal.
a.The driveshaft lock nut should be replaced with new ones.
b. After installation driveshaft lock nut, stake the lock nut using a chisel and hammer as shown in the
illustration below.
INSPECTION
1.Check the driveshaft boots for damage and deterioration.
2. Check the ball joints for wear and damage.
3. Check the splines for wear and damage.
4. Check the dynamic damper for cracks and wear.

INSPECTION
1.Check the drive shaft spline for wear or damage.
2. Check that there is no water or foreign material in the BJ.
3. Check the spider assembly for roller rotation, wear or corrosion.
4. Check the groove inside the UTJ case for wear or corrosion.
5. Check the dynamic damper for damage or cracks.
DISASSEMBLY
a.Do not disassemble the BJ assembly.
b. The Driveshaft joint uses special grease. Do not subtitute with another type of grease.
c. The Boot band should be replaced with a new one.
1. Remove the TSJ boot band and pull the boot from TSJ outer race.
Be careful not to damage it.

2.Remove the circlip using a screwdriver.
3.Remove the driveshaft from TSJ outer race.
4.Remove the snap ring and disassemble the spider assembly from the shaft.
5. Clean the spider assembly.
6. Remove the BJ boot band and removal of the TSJ boot and the BJ boot.
If the boot is reused, wrap a tape around the driveshaft splines to protect the boot.

a.Do not disassemble the BJ assembly.
b. Special grease must be applied to the drive shaft joint. Do not substitute with another type of grease.
c. The boot band should be replaced with a new one.
1. Remove the clip (B) from drive shaft splines (A) of the transaxle side.
2.Remove both boot bands from the transaxle side UTJ case.
3.Pull out the boot from the transaxle side joint(UTJ).
4. When separating the joint and boot (A), remove the grease from the UTJ case (B).
a.Be careful not to damage the boot.
b. According to ullustration below, put alignment marks across spider roller assembly (A), UTJ case (B), and
shaft splines (C) to aid in reassembly.

5.Using a plier or flat- tipped ( - ) screwdriver, remove the snap ring (A).
6.Remove the spider assembly (B) from drive shaft (A) by using the Special Tool(09495- 33000).
7.Clean the spider assembly.
8. Remove the boot (A), of the transaxle side joint(UTJ).
Wrap tape (B) around the driveshaft splines (C) to protect the boot (A).

14.Pull out the joint(BJ) boot on the side of wheel into the transaxle direction.
Be careful not to damage the boot.
REASSEMBLY
1.Wrap tape around the drive shaft splines (UTJ side) to prevent damage to the boots.
2. Apply grease to the joint(BJ) boot on the side of wheel and install the boots.
3. Install the bands to both boots.
4.Using clamp, secure the boot bands.
Clearance (A) : 2.0 mm (0.079 in.) or less
5.To install the dynamic damper, keep the BJ shaft in a straight line and secure the dynamic damper with the
dynamic damper bands.
6. Install the UTJ boot bands and UTJ boot.
7. Using the alignment marks (D) made during disassembly as a guide, install the spider assembly (A) and snap ring
(B) on the driveshaft splines (C).

(B) on the driveshaft splines (C).
8.Add the specified grease to the joint(UTJ) boot as mush as wiped away at inspection.
9. Install the boots.
10. To control the air in the UTJ boot, keep the specified distance between the boot bands when they are tightened.
Standard value [A]
Items Standard (A) mm(in)
LH RH
2.9 Diesel M/T 505.4 (19.90)466.8 (18.38)
2.9 Diesel A/T 507.5 (19.98)466.9 (18.38)
3.8 Gasoline A/T 557.1 (21.93)570.7 (22.47)
11. Install both sides of the boot bands by using SST (09495- 39100).

Rear shock absorber bracket mounting bolt(to body)80 ~ 1108 ~ 1157.9 ~ 79.5
Rear shock absorber bracket mounting nut(to body) 90 ~ 1209~ 1265.1 ~ 86.8
Rear shock absorber nut (to rear knuckle) 140 ~ 16014 ~ 16101.2 ~ 115.7
Rear upper arm ball joint nut (to rear knuckle) 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear upper arm self - locking nut (to cross member) 160 ~ 18016 ~ 18115.7 ~ 130.2
Rear lower arm mounting bolt (to rear knuckle) 160 ~ 18016 ~ 18115.7 ~ 130.2
Rear lower arm mounting nut (to cross member) 200 ~ 27020 ~ 27144.7 ~ 195.3
Rear assist arm mounting bolt (to rear knuckle) 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear assist arm mounting nut (to cross member) 90 ~ 1209 ~ 1265.1 ~ 86.8
Trailing arm bracket mounting nut (to body) 80 ~ 1108 ~ 1157.9 ~ 79.5
Trailing arm self - locking nut (to rear knuckle) 80 ~ 1008 ~ 1057.9 ~ 72.3
Trailing arm mounting bolt(to bracket) 160~ 18016 ~ 18115.7 ~ 130.2
Rear stabilizer bar bracket mounting bolt(to cross member) 39 ~ 603.9 ~ 6.028.2 ~ 43.4
Rear stabilizer link self - locking nut(to trailing arm) 50 ~ 655.0 ~ 6.536.2 ~ 47.0
Wheel nut 90 ~ 1109 ~ 1165.1 ~ 79.5
Rear cross member to body 160 ~ 18016 ~ 18115.7~130.2
Replace the self - locking nuts with new ones after removal.
LUBRICANTS
Items The Recommended Quantity
Front lower arm ball joint Boot : CGMS03 (CMS - H006)
Ball seat : CGMS02 (CMS - H006)
As required
Rear upper arm ball joint
Boot : CGMS03 (CMS - H006)
Ball seat : CGMS01 (CMS - H006)
Rear assist arm ball joint
Stabilizer link ball joint(Front Rear)