horn KIA CARNIVAL 2007 Workshop Manual

ClassSize code Piston outer diameter
A A86.67 ~ 86.68mm
(3.4122 ~ 3.4126in.)
B -86.68 ~ 86.69mm
(3.4126 ~ 3.4130in.)
C C86.69 ~ 86.70mm
(3.4130 ~ 3.4134in.)
8. Select the proper piston related to the cylinder bore class.
Clearance : 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
CYLINDER BORING
1.The over size piston is chosen on the maximum inner diameter of the cylinder.
The piston size mark is on the top surface of the piston.
2. Measure the outer diameter of the piston which is installed before.
3. Calculate the new bore size with the measurement in the step 2.
New bore size = measured outer diameter of piston + 0.02 ~ 0.04mm(0.0008~0.0016in.)[clearance] -
0.01mm(0.0004in.)[for horning]
4. Bore the cylinder to the calculated size.
Bore the cylinders in firing order to prevent the cylinders from be twisted by high temperature.
5. Stop boring and start horning for the proper clearance.
6. Measure the clearance between a piston and a cylinder.
Specification
0.02 ~ 0.04mm(0.0008 ~ 0.0016in.)
Bore all the cylinders with the same over size.
PISTON AND RINGS
1.Clean pistons.
(1) Using a gasket scraper, remove the carbon from the piston top.
(2) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.
(3) Using solvent and a brush, thoroughly clean the piston.
Do not use a wire brush.
2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the
piston.

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Disconnect the negative terminal (A) from the battery and then wait for 30 seconds.
2.Loosen the bolts in the illustration and then remove the horn pad (A).
3.Disconnect the connectors and remove the steering wheel lock nut.

2007 > 2.7L V6 GASOLINE >
REMOVAL
1.Disconnect the battery negative cable and wait at least three minutes before beginning work.
2. Remove the airbag module mounting bolts.
3.Disconnect the horn connector(A).
4.Release the connector locking pin(B), then disconnect the driver airbag module connector(C).
The removed airbag module should be stored in a clean, dry place with the pad cover face up.
5. Remove the steering wheel and steering wheel column cover(Refer to ST group in the Workshop Manual).
6. Disconnect the clock spring and horn connector, then remove the clock spring.
INSTALLATION
1.Disconnect the negative ( - ) cable from battery and wait for at least three minutes.

2.Remove ignition key from the vehicle.
3. Connect the clock spring harness connetor and horn harness connector to the clock spring.
4. Set the clock spring on neutral position and after turning the front wheels to the straight- ahead position, install the
clock spring.
5. Install the steering wheel column cover and the steering wheel. (Refer to ST group)
6. Connect the Driver Airbag (DAB) module connector and horn connector, then install the Driver Airbag (DAB)
module on the steering wheel.
7. Secure the Driver Airbag (DAB) with the new mounting bolts.
Tightening Torque (DAB Mounting Bolt)
: 0.8 ~ 1.1 kgf.m (7.9 ~ 10.8 Nm, 5.8 ~ 8.0 lb.ft)
8.Connect the battery negative cable.
9. After installing the airbag, confirm proper system operation:
a. Turn the ignition switch ON; the SRS indicator light should be turned on for about six seconds and then go off.
b. Make sure horn button works.
INSPECTION
Driver Airbag (DAB)
If any improper parts are found during the following inspection, replace the airbag module with a new one.
Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester, accidental airbag deployment will result in serious
personal injury.
1. Check pad cover for dents, cracks or deformities.
2. Check the airbag module for denting, cracking or deformation.
3. Check hooks and connectors for damage, terminals for deformities, and harness for binds.

Horn

2007 > 2.7L V6 GASOLINE >
REPLACEMENT
1.Remove the bolt from the high pitch horn and the low pitch horn and disconnect the horn connector, then remove
the horn.
2.Installation is the reverse of removal.
INSPECTION
Test the horn by connecting battery voltage to the terminal 1, and ground terminal 2.
The horn should make a sound. If the horn fails to make a sound, replace it.
ADJUSTMENT
Operate the horn, and adjust the tone to a suitable level by turning the adjusting screw.
After adjustment, apply a small amount of paint around the screw head to keep it from loosening.

3.Check for continuity between the terminals in each position according to the table.
BURGLAR HORN
1.Remove the burglar horn after removing 2 bolts and disconnect the 2P connector from the burglar horn.
2. Test the burglar horn by connecting battery power to the terminal 1 and ground the terminal 2.
3.The burglar horn should make a sound. If the burglar horn fails to make a sound replace it.

Horn
1.Working Conditions
Required key positions:
a. At any position of the key in the cylinder for the horn stalk activation,
b. At Key out from the key cylinder for the horn lock activation or for panic activation.
2. Functional Diagram
Burglar Alarm Function
Burglar Alarm
1.Basic Concept
a. The following functions are related to the RKE and burglar alarm systems..
a. Door locking
b. Door unlocking
c. PSD open/close (both for left and right)
d. PTG open/close
e. Panic
b. If IGN key is inserted into the key cylinder, the RKE transmitter functions are inoperative..
c. Door locking by RKE signal:
a. Whenever this signal is received, door LOCK pulse is always issued.
b. Hazard lamp flashes one time for 1 second depending on the burglar alarm state.
c. This signal will make the system possible to enter into the ARM state (or PREARM state depending on the
vehicle condition).
d. Door unlocking by RKE signal.
a. Whenever this signal is received, door UNLOCK pulse is always issued.
b. Hazard lamp flashes two times whenever the key fob unlock signal is received.
c. This signal will make the system possible to enter into the DISARM or 30sec DELAY state depending on
Condition A is true or not.
e. LH or RH PSD open/close by RKE signal.
a. Only with the information received by RKE, the burglar alarm system cannot distinguish the OPEN signal from
CLOSE signal.

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

18Burglar Alarm horn ON/OFFContiuously ON with 60
cycles per minute, Duty:50%
RAM ACTUATOR LIST No. Description ValueControl
1 Room Lamp LS ON/OFFContinuously ON
2 Room Lamp LS Door ON/OFFContinuously ON
3 Luggage Lamp LS ON/OFFContinuously ON
4 LQG Motor Close ON/OFF3 sec ON then OFF (once)
5 LQG Motor Open ON/OFF3 sec ON then OFF (once)
6 RQG Motor Close ON/OFF3 sec ON then OFF (once)
7 RQG Motor Open ON/OFF3 sec ON then OFF (once)
8 RSD Power Window Up ON/OFF3 sec ON then OFF (once)
9 RSD Power Window Down ON/OFF3 sec ON then OFF (once)
10 LSD Power Window Up ON/OFF3 sec ON then OFF (once)
11 LSD Power Window Down ON/OFF3 sec ON then OFF (once)
12 LH PSD Open Close Signal ON/OFF0.5 sec ON then OFF
(once)
13 RH PSD Open Close Signal ON/OFF0.5 sec ON then OFF
(once)
14 PTG Open Close Signal ON/OFF0.5 sec ON then OFF
(once)
15 PSD PTG On Off Signal ON/OFFContinuously ON
16 Park Signal ON/OFFContinuously ON
17 Start Signal ON/OFFContinuously ON
18 Rear Defog ON/OFFContinuously ON
19 Rear Fog Lamps ON/OFFContinuously ON
20 Right Turn Signal Lamp ON/OFFContiuously ON with (80 +/ -
5) cycles per minute, Duty: 50%
21 Left Turn Signal Lamp ON/OFFContiuously ON with (80 +/ -
5) cycles per minute, Duty: 50%
22 Back Up Lamp Back Up Warning System Unit ON/OFFContinuously ON
23 Left/Right Tail Licence Side Marker ON/OFFContinuously ON
24 Door Lock ON/OFF0.5 sec ON then OFF
(once)
25 Door Unlock ON/OFF0.5 sec ON then OFF
(once)
26 Rear Wiper Motor ON/OFF5 sec ON then OFF (once)
27 Rear Blower Switch
& Rear Monitor
illumination ON/OFF
Continuously ON
0.5 sec ON then OFF