diesel KIA CARNIVAL 2007 Workshop Manual

2007 > 2.7L V6 GASOLINE >
IDENTIFICATION NUMBER DESCRIPTION
VEHICLE IDENTIFICATION NUMBER
1 : Geographic zone
- K = Korea
2 : Manufacturer
- N = Kia motor company
3 : Vehicle type
- A = Passenger car
4 - 5 : Vehicle Line/Series
- MB = VQ
- MC = EP
6 - 7: Body type
- 75 = Coach & GVW 2271 ~ 2720 kg
- 76 = Long coach & GVW 2271 ~ 2720 kg
8 : Engine type
- 1 = J2.9 Diesel
- 2 = µ 2.7
- 3 = λ3.8 Gasoline
9 : Transmission type
- 2 : Manual
- 5 : Automatic
10 : Model year
- 5 = 2005, 6 = 2006, 7 = 2007
11 : Plant location
- 6 = Soha plant
12 - 17 : Production sequential number
- 000001 ~ 999999
ENGINE IDENTIFICATION NUMBER
GASOLINE
1. Engine fuel
- G : Gasoline
2. Engine range
- 4 : 4 cycle 4 cylinder
- 6 : 4 cycle 6 cylinder
3. Engine development order
- D : Lambda engine
4. Engine capacity
- E : 2656 cc (µ- engine)
5. Production year
- 5 : 2005, 6 : 2006
6. Engine production sequence number
- 000001 ~ 999999

7.Using a plastic hammer, disconnect the driveshaft (A) from the front hub assembly (B).
8.Removal of the driveshaft [RH].
a. [Gasoline 3.8 only]
Remove the heat protector (A).
b.Remove the inner shaft bearing bracket assembly mounting bolts (A).
Tightening torque Nm (Kgf.m, lb - ft):
Diesel: 43 ~ 63 (4.3 ~ 6.3, 31 ~ 46)

(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).

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
FRONT SUSPENSION SYSTEM
Items Specification
Type Macpherson strut
Shock Absorber Type
Gas
Stroke mm (in) 195.5 (7.70)
Expansion mm (in) 595.5 ± 3 (23.44 ± 0.12)
Compression mm (in) 400 + 3, - Free (15.75 + 3,
Free)
I.D. Color DIESEL
WHITE
GASOLINE RED
Damping force (0.3 m/s) DIESEL
Expansion N(kgf)
1265 ± 186 (129 ± 19)
Compression N (kgf) 618 ± 108 (63 ± 11)
GASOLINEy Expansion N(kgf)
980 ± 220 (100 ± 15)
Compression N (kgf) 588 ± 118 (60 ± 12)
Spring DIESEL
Free height mm (in)
418.9 (16.49)
Load(kg) I.D. Color594.8~606.7
Yellow 2 point
y
582.9~594.7 yYellow 1 point
GASOLINE Free height mm (in)
415.9 (16.37)
Load(kg) I.D. Color550.0~561.2
Green 2 point
y
538.8~549.9 Green 1 point
REAR SUSPENSION SYSTEM Items Specification
Type Multi Link
Shock Absorber Type
Gas
Stroke mm (in) 170 (6.68)
Expansion mm (in) 478.0 ± 3 (18.82 ± 0.12)
Compression mm (in) 308 + 3, - Free
(12.13 + 0.12, - Free)
I.D. Color DIESEL
WHITE
GASOLINE RED
Damping force (0.3 m/s) DIESEL
Expansion N(kgf)
1540 ± 216 (157 ± 22)
Compression N (kgf) 647 ± 127 (66 ± 13)
GASOLINE Expansion N(kgf)
1422 ± 206 (145 ± 21)
Compression N (kgf) 549 ± 108 (56 ± 11)
DIESEL Free height mm (in)
286.7 (11.29)
Load(kg) I.D. Color642.2~674.7
Yellow 2 point
y

2007 > 2.7L V6 GASOLINE >
SPECIFICATIONS
Items Specifications
Steering column/ shaft Type
Tilt
Tilt stroke +7°/ - 11.7°
Steering gear Type
Rack & pinion
Rack stroke VRS On
148 mm (5.827 in)
VRS Off 156 mm (6.142 in)
Power steering pump Type
Vane
Diesel Relief pressure
90 kgf/cm²
Discharge 9.6 cc/rev
Gasoline Relief pressure
90 kgf/cm²
Discharge 10.5 cc/rev
SERVICE STANDARD
Items Specifications
Steering wheel free play 30 mm (1.12 in)
Steering angle VRS on
Inner
38.64°
Outer 31.78°
VRS off Inner
41.91°
Outer 33.54°
TIGHTENING TORQUE
Items NmKgf.m Lb- ft
Steering wheel lock nut 40 ~ 504.0 ~ 5.0 29 ~ 36
Steering column mounting bolts and nut 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Bolt connecting steering column to universal
joint 15 ~ 20
1.5 ~ 2.010.8 ~ 14.5
Bolt connecting universal joint to steering gear 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Steering column mounting bolts and nut 13 ~ 181.3 ~ 1.89.4 ~ 13.0
Tie rod end castle nut 35 ~ 453.5 ~ 4.5 25 ~ 33
Front lower arm ball joint assembly bolts 90 ~ 1209.0 ~ 12.0 65 ~ 87
Stabilizer link to strut assembly nut 100 ~ 12010.0 ~ 12.0 72 ~ 87
Rear roll stopper to sub- frame bolts 50 ~ 605.0 ~ 6.0 36 ~ 43
Pressure tube to valve body housing nut 12 ~ 181.2 ~ 1.8 9 ~ 13
Pressure tube to oil pump eye bolt 65 ~ 756.5 ~ 7.5 47 ~ 54
Return tube to valve body housing nut 12 ~ 181.2 ~ 1.8 9 ~ 13
Power steering gear box to sub- frame bots 90 ~ 1109.0 ~ 11.0 65 ~ 80
LUBRICANT
Item Lubricant Quantity
Power steering fluid PSF - 31.1 L

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Remove the both front wheel & tire assemblies.
2. Drain the power steering fluid.
3. Remove the bolt (A) connecting steering column to universal joint.
Tightening torque Nm (kgf.m, lb - ft):
13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0)
4.Disconnect the pressure tube (A) from the power steering oil pump by loosening eye bolt.
Tightening torque Nm (kgf.m, lb - ft):
65 ~ 75 (6.5 ~ 7.5, 47 ~ 54)
[Diesel]
[Gasoline]
5.Disconnect the return hose (A)

[Diesel]
[Gasoline]
6.Loosen the split pin and castle nut, and then remove the tie rod end (A) from the knuckle by using a SST (09568-
4A000).
Tightening torque Nm (kgf.m, lb - ft):
50 ~ 55 (5.0 ~ 5.5, 36 ~ 40)

2007 > 2.7L V6 GASOLINE >
COMPONENTS
[Diesel]
[Gasoline]

2007 > 2.7L V6 GASOLINE >
REPLACEMENT
1.Drain the power steering fluid.
2. Disconnect the pressure tube (A) and suction tube (B) from the power steering oil pump.
Tightening torque Nm (kgf.m, lb - ft):
55 ~ 65 (4.5 ~ 5.5, 40 ~ 47)
[Diesel]
[Gasoline]
3.Disconnect the pressure tube (A) and return tube from the valve body housing.
Tightening torque Nm (kgf.m, lb - ft):
12 ~ 18 (1.2 ~ 1.8, 9 ~ 13)
4.Remove the brackets of the pressure tube and hose from the sub- frame.

[Diesel]
[Gasoline]
5.Remove the bracket of the return tube and hose.
[Diesel]
[Gasoline]