headlamp KIA CARNIVAL 2007 Workshop Manual

2007 > 2.7L V6 GASOLINE >
ON-VEHICLE INPECTION
a.Check that the battery cables are connected to the correct terminals.
b. Disconnect the battery cables when the battery is given a quick charge.
c. Never disconnect the battery while the engine is running.
CHECK BATTERY VOLTAGE
1.If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn the ignition switch OFF and turn off the electrical systems.
3. Measure the battery voltage between the negative ( - ) and positive (+) terminals of the battery.
Standard voltage : 12.5 ~ 12.9V at 20°C(68°F)
If the voltage is less than specification, charge the battery.
CHECK THE BATTERY TERMINALS AND FUSES
1.Check that the battery terminals are not loose or corroded.
2. Check the fuses for continuity.
INSPECT DRIVE BELT
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should
be replaced.
VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES
1.Check that the wiring is in good condition.
2. Check that there is no abnormal noise from the alternator while the engine is running.
CHECK DISCHARGE WARNING LIGHT CIRCUIT
1.Warm up the engine and then turn it off.
2. Turn off all accessories.
3. Turn the ignition switch "ON". Check that the discharge warning light is lit.
4. Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.
INSPECT CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE
This test determines whether or not the wiring between the alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.
PREPARATION

1.Turn the ignition switch to "OFF".
2. Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the "B"
terminal of alternator and the ( - ) lead wire of ammeter to the output wire. Connect the (+) lead wire of voltmeter to
the "B" terminal of alternator and the ( - ) lead wire of voltmeter to the (+) terminal of battery.
TEST
1.Start the engine.
2. Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.
RESULT
1.The voltmeter may indicate the standard value.
Standard value: 0.2V max
2. If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the alternator "B" terminal to the battery (+) terminal. Check for loose connections, color
change due to an over - heated harness, etc. Correct them before testing again.
3. Upon completion of the test, set the engine speed at idle.
Turn off the headlamps, blower motor and the ignition switch.
OUTPUT CURRENT TEST
This test determines whether or not the alternator gives an output current that is equivalent to the normal output.
PREPARATION
1.Prior to the test, check the following items and correct as necessary.
Check the battery installed in the vehicle to ensure that it is good condition. The battery checking method is
described in the section "Battery".
The battery that is used to test the output current should be one that has been partially discharged. With a fully
charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the section "Inspect
drive belt".
2. Turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Disconnect the alternator output wire from the alternator "B" terminal.
5. Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected output wire. Be sure
to connect the ( - ) lead wire of the ammeter to the disconnected output wire.
Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
6. Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B"
terminal and ( - ) lead wire to a good ground.
7. Attach an engine tachometer and connect the battery ground cable.
8. Leave the engine hood open.

TEST
1.Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter reads 0V, and the
open circuit in the wire between alternator "B" terminal and battery ( - ) terminal or poor grounding is suspected.
2. Start the engine and turn on the headlamps.
3. Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the engine speed to 2,500
rpm and read the maximum output current value indicated by the ammeter.
After the engine start up, the charging current quickly drops.
Therefore, the above operation must be done quickly to read the maximum current value correctly.
RESULT
1.The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is in good
condition, remove the alternator from the vehicle and test it.
Limit value : 70Ë of the rated current
a.The nominal output current value is shown on the nameplate affixed to the alternator body.
b. The output current value changes with the electrical load and the temperature of the alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the headlamps on the
cause discharge of the battery, or use the lights of another vehicle to increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself or ambient
temperature is too high.
In such a case, reduce the temperature before testing again.
2. Upon completion of the output current test, lower the engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine tachometer.
5. Connect the alternator output wire to the alternator "B" terminal.
6. Connect the battery ground cable.
REGULATED VOLTAGE TEST
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
PREPARATION
1.Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking method is described in the
section "Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect drive
belt".
2. Turn ignition switch to "OFF".
3. Disconnect the battery ground cable.
4. Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the ( - ) lead to good ground or the battery ( - ) terminal.
5. Disconnect the alternator output wire from the alternator "B" terminal.

2007 > 2.7L V6 GASOLINE >
REPLACEMENT
a.Take care not to damage the hood and body.
b. When removing the clips, use a clip remover.
1. Remove the following items.
a. Headlamp assembly.
b. Front bumper.
c. Side garnish (B), mud guide (C), cover (D)
2. After loosening the fender mounting bolts, remove the fender (A).
3. Installation is the reverse of removal.

2007 > 2.7L V6 GASOLINE >
REPLACEMENT
FRONT BUMPER COVER REPLACEMENT
a. Put on gloves to protect your hands.
b. When prying with a flat- tipped screwdriver, wrap it with protective tape to prevent damage.
c. Take care not bend or scratch the cover and other parts.
1. Disconnect the connector (C).
2. Remove the headlamp (B), under cover (A).
3. Loosen the front bumper mounting screws and clips.
4. Remove the front bumper.
5. Remove the connector (C).
6. Installation is the reverse of removal.

2007 > 2.7L V6 GASOLINE >
DESCRIPTION
All modules are linked a low speed CAN network.
The input information for the modules is coming from both the CAN network and the hardware components
(actuatorsand sensors).
a. FAM (Front Area Module)
a. Headlamp low/high beam control (with DRL)
b. Park lamp control
c. Front fog lamp control
d. Front turn signal lamp control
e. Windshield wiper control
f. Windshield deicer
g. Diagnostics
b. IPM (In - Panel Module)
a. RKE (Remote Keyless Control)
b. VAS (Voice Alarm System)
c. Ignition key hole illumination
d. Switch indicators control
e. Panel light control
f. Seat belt warning
g. Auto light/DRL control (Logic)
h. Windshield/Rear wiper control (Logic)
i. Turn and Hazard lamp control (Logic)
j. Central door lock (Logic)
k. Windshield deicer timer
l. Rear glass defog timer
m. Gateway for ISO- 9141 (K- Line)
c. RAM (Rear Area Module)
a. Tail lamp control
b. Turn and Hazard lamp control
c. Back up lamp control
d. Rea fog lamp control
e. Stop lamp outage detection
f. Sliding door power window/Quarter glass control
g. Room lamp control
h. Rear wiper control
i. Rear glass defog
j. Fuel filler door open solenoid control
d. ADM (Assist Drive Module)
e. DDM (Driver Drive Module)
MODULE INTRODUCTION
FAM/IPM/RAM consists of a power board and an electronic board. The power board contains circuit protection devices
and switching devices. The electronic board uses Intelligent Power Switching (IPS) for HS/LS load control, logic
functions and CAN/K- Line communication. The power board and electronic board are connected with pin blocks for
the Front Area Module (FAM) and VCD (Variable Connection Displacement) for the In- Panel Module (IPM) and the
Rear Area Module (RAM).

b.When the multifunction switch is not in postion headlamps turned on or autolight
c. 20 mn after the driver door is open
d. 20mn after IGN leaves the positions RUN to ACC or OFF
e. If IPM receives RKE "LOCK" command two times
3. Escort function enables only "Head Lamp Low Beam", so Park/Tail lamp should be turned off when driver door is
opened at key out (Battery Saver function).
4. Functional Diagram
Interior Lighting Functions
Room Lamps
1.The room lamps are can be controlled manually using the 3 - state (ON, DOOR, OFF) switch or by the Rear Area
Module (RAM). A main switch, located to the left of the steering wheel, is used as a master control switch. The
operating logic of the lamps will vary based on the position of the main switch ON, DOOR, or OFF).
2. Working conditions
a. The functioning depends on the key position in the key cylinder (OFF, ACC, RUN or START)
b. When the key goes in RUN or START position while the room lamps are decaying, then the room lamps are
turned off immediately.
c. When the Ignition key position is RUN or START and the last door is closed then the room lamps are OFF.
d. If the room lamps have been activated using the RKE UNLOCK function, and the ignition switch is turned to the
RUN or START position, the room lamps will be immediately turned OFF..
e. If the Ignition sw status is in RUN or START and Unlock information occurs, then the room lamp status is not
changed.
f. When the system enters to ARM WAIT mode by Remote Key or Mechanical cylinder lock switches the Room
lamp should be turned off immediately.
g. If there is RKE Lock signal at any door open, all doors should be locked first and wait for the all door close. No
action is taken while the Open Door status is OPEN and the doors are locked. Then when Open Door status
changes from OPEN to CLOSE, Room lamps will be OFF immediately.
h. The 30sec timer does not depend on the key reminder status.
i. If the main switch is changed to ON from DOOR after 20minute lamp OFF, all the lamps are turned ON.
j. If the Open Door status changes from OPEN to CLOSE (all doors close) when ignition switch is on RUN
position, room lamps and door courtesy lamps should turn off immediately (Do not decay off).
k. After 20minute Room Lamp OFF at door open, Room lamps are turned ON again when:
a. One of the door open switch's status changes. (Open to Close or Close to Open)
b. Ignition key is in RUN or START Position.
c. Receiving an UNLOCK event while a door is open and Main Room Lamp Switch is in the DOOR position.
l. For the room lamps, when the 20m timer is running and any of the side doors is opened the timer is restarted.
3. Functional Diagram

2.The IPM communicates with the diagnostic tester directly. But other units operate self diagnostic, input/output
monitoring and actuator operation via the IPM using the CAN communication.
INPUT MONITORING
IPM (In- Panel Module)
No. Input switch Unit
1 IPM Node Availability PRESENT/NOT PRESENT
2 FAM Node Availability PRESENT/NOT PRESENT
3 RAM Node Availability PRESENT/NOT PRESENT
4 DDM Node Availability PRESENT/NOT PRESENT
5 ADM Node Availability PRESENT/NOT PRESENT
6 IMS Node Availability PRESENT/NOT PRESENT
7 CLU Node Availability PRESENT/NOT PRESENT
8 IPM Node Failure FAILURE/ O.K
9 FAM Node Failurey FAILURE/ O.K
10 RAM Node Failure FAILURE/ O.K
11 DDM Node Failure FAILURE/ O.K
12 ADM Node Failure FAILURE/ O.K
13 IMS Node Failure FAILURE/ O.K
14 CLU Node Failure FAILURE/ O.K
15 Auto Head lamp ON/OFF
16 Headlamp low beam ON/OFF
17 High beam ON/OFF

16B1646 S/W RESCUE MODE Module enters rescue mode
17 B1647 VAS ERROR No VAS chip transition from busy to not busy for more than 5 s after
a VAS message command has been issued
FAM DTC List No. DTC
Code DTC
Passiblecause
1 B1624 EEPROM FAILURE Failed attempt to read or write EEPROM
2 B1627 EEPROM CORRUPTION Data in EEPROM is not coherent
3 B1646 S/W RESCUE MODE As soon as the module enters rescue mode
4 B2119 WINDSHIELD DEFOG
RELAY FAIL Windshield defog relay failure
5 B2521 BRAKE CIRCUIT OPEN OR
FUSE FAIL Stop lamp fuse failure
6 B2535 RIGHT T/SIGNAL LAMP
SHORT TO GND Right turn signal lamp circuit short to ground error
7 B2537 RIGHT T/SIGNAL LAMP
OPEN Right turn signal lamp circuit open error
8 B2539 LEFT T/SIGNAL LAMP
SHORT TO GND Left turn signal lamp circuit short to ground error
9 B2541 LEFT T/SIGNAL LAMP
OPEN Left turn signal lamp circuit open error
10 B2543 RIGHT H/LAMP HIGH
SHORT TO GND Right headlamp high circuit short to ground error
11 B2545 RIGHT H/LAMP HIGH
OPEN Right headlamp high circuit open error
12 B2547 LEFT H/LAMP HIGH
SHORT TO GND Left headlamp high circuit short to ground error
13 B2549 LEFT H/LAMP HIGH OPEN Left headlamp high circuit open error
14 B2551 RIGHT H/LAMP LOW
SHORT TO GND Right headlamp low circuit short to ground error
15 B2553 RIGHT H/LAMP LOW
OPEN Right headlamp low circuit open error
16 B2555 LEFT H/LAMP LOW
SHORT TO GND Left headlamp low circuit short to ground error
17 B2557 LEFT H/LAMP LOW OPEN Left headlamp low circuit open error
18 B2559 FR FOG LAMP SHORT TO
GND Right front fog lamp circuit short to ground error
19 B2561 FR FOG LAMP OPEN Right front fog lamp circuit open error
20 B2563 FL FOG LAMP SHORT TO
GND Left front fog lamp circuit short to ground error
21 B2565 FL FOG LAMP OPEN Left front fog lamp circuit open error
22 B2571 RIGHT P/LAMP SHORT TO
GND Right parking lamp circuit short to ground error
23 B2573 RIGHT P/LAMP OPEN Right parking lamp circuit open error
24 B2575 LEFT P/LAMP SHORT TO
GND Left parking lamp circuit short to ground error

2Rear Defog Switch Indicator Output ON/OFFContinuously ON
3 Rear Fog Lamp Switch Indicator Output ON/OFFContinuously ON
4 VAS Switch Indicator Output ON/OFFContinuously ON
5 Back Up Signal Output ON/OFFContinuously ON
6 Micro Burglar Relay Drive Output ON/OFFContinuously ON
7 Ignition Key Hole Illumination ON/OFFContinuously ON
8 Adjustable Pedal On Off Signal Output ON/OFFContinuously ON
9 Power Feed To Sunroof Relay Coil ON/OFFContinuously ON
10 Horn Relay Drive ON/OFF0.5 sec ON then OFF
11 Sound Mute Signal Output ON/OFFContinuously ON
12 Panel Lights Trip Computer Output ON/OFFContinuously ON
13 Micro MTS Burglar Alarm Output ON/OFFContinuously ON
14 Auto Light Sensor 5V Ref ON/OFFContinuously ON
15 Burglar Alarm Indicator ON/OFFContinuously ON
16 AV Tail Output ON/OFFContinuously ON
17 VAS ON/OFFOne Issue of voice alarm
message
18 Chime ON/OFFContinuously ON with 0.6
sec period
FAM ACTUATOR LIST No. Description ValueControl
1 Front Washer ON/OFF1 sec ON then OFF (once)
2 Rear Washer ON/OFF2 sec ON then OFF (once)
3 Right Headlamp High ON/OFFContinuously ON
4 Right Headlamp Low ON/OFFContinuously ON
5 Right Lamp Park ON/OFFContinuously ON
6 Right Fog Lamp ON/OFFContinuously ON
7 Right Turn Signal ON/OFFContiuously ON with (80 +/ -
5) cycles per minute, Duty: 50%
8 Left Headlamp High ON/OFFContinuously ON
9 Left Headlamp Low ON/OFFContinuously ON
10 Left Lamp Park ON/OFFContinuously ON
11 Left Fog Lamp ON/OFFContinuously ON
12 Left Turn Signal ON/OFFContiuously ON with (80 +/ -
5) cycles per minute, Duty: 50%
13 IGN2 Control ON/OFFContinuously ON
14 Windshield Defog Timer ON/OFFContinuously ON
15 Wiper On Off ON/OFFContinuously ON
16 Wiper Low speed ON/OFF3 wiping with LOW speed
17 Wiper High speed ON/OFF3 wiping with HIGH speed