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CHAPTER 1:

General Information

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Summary of Contents for Kia Carnival 2007

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CHAPTER 1: General Information…
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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…
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TRANSMISSION IDENTIFICATION NUMBER AUTOMATIC 1. Modle — U : A5HF1 2. Production year — 5 : 2005, 6 : 2006, 7 : 2007 3. Gear ratio — K : 3.333 4. Detailed chassification — FD : 3.8D 5. Spare 6. Transaxle production sequence number — 000001 ~ 999999 MANUAL 1.
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Always use Genuine Kia parts and recommedended fluid. Using any other type of parts and fluid can cause serious damaged if the vehicle.RECOMMENDED LUBRICANTS LUBRICANTS CAPACITIES Description Engine oil Oil pan 4.2 (4.44, 3.70) Oil filter 0.3 (0.32, 0.26) Total 4.5 (4.76, 0.26)
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For best performance and maximum protection of all types of operation, select only those lubricants which. a. Satisfy the requirements of the API classification. b. Have the proper SAE grade number for expected ambient temperature range. c. Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.
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CHAPTER 2: Engine Mechanical System…
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2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Tool (Number and name) Illustration Crankshaft front oil seal Installation of the front oil seal installer (09214-33000) Torque angle adapter Installation of bolts & nuts needing an angular (09221-4A000) method Valve stem seal remover Removal of the valve stem seal (09222-29000) Valve stem seal installer…
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Crankshaft rear oil seal Installation of the crankshaft rear oil seal installer (09231-33000) Oil pan remover Removal of oil pan (09215-3C000) Valve guide installer Removal and installation of the valve guide (09221-3F100 A/B)
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2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Symptom Suspect area Remedy Engine misfire with Worn crankshaft bearings. Replace the crankshaft and bearings as abnormal internal Loose or impropes engine drive plate. required. lower engine noises. Repair or replace the drive plate as required. Worn piston rings.
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noise,regardless of Loose or damaged drive plate. Repair or replace the drive plate. engine speed. Damaged oil pan, contacting the oil pump a. Inspect the oil pan. screen. b. Inspect the oil pump screen. c. Repair or replace as required. Oil pump screen loose, damaged or a.
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Seized crankshaft or connecting rod bearings. a. Inspect crankshaft and connecting rod bearing. b. Repair as required. Bent or broken connecting rod. a. Inspect connecting rods. b. Repair as required. Broken crankshaft. a. Inspect crankshaft. b. Repair as required.
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2007 > 2.7L V6 GASOLINE > Compression pressure inspection If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. Warm up the engine until the normal operating temperature becoming 80~95°C(176~203°F). 2. Remove the surge tank. 3.
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1. Remove the engine cover. 2. Remove air cleaner assembly. 3. Remove the surge tank. 4. Remove the cylinder head cover. (1) Disconnect the ignition coil connector and remove the ignition coil. (2) Remove the cylinder head cover. 5. Set the piston of the No.1 cylinder to TDC(Top Dead Center) position. (1) Turn the crankshaft pulley clockwise and align its groove with the timing mark «T»…
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Specification Limit (Engine coolant temperature : 20°C [68°F]) Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.) Exhaust : 0.20 ~ 0.40mm (0.0079 ~ 0.0157in.) (2) Turn the crankshaft pulley one revolution (360°) clockwise and align the groove with the timing mark «T» of the timing chain cover.
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N : Thickness of new tappet Intake : N = T + [A — 0.20mm(0.0079in.)] Exhaust : N = T + [A — 0.30mm (0.0118in.)] (8) Select a new tappet with a thickness as close as possible to the calculated value. Tappets are available with 41different size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm (0.1417in.) (9) Place a new tappet on the cylinder head.
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2007 > 2.7L V6 GASOLINE > SPECIFICATIONS Description Specifications Limit General Type V-type, DOHC Number of cylinder Bore 86.7mm(3.4134in.) Stroke 75mm(2.9528in.) Total displacement 2,656cc Compression ratio 10.4 Firing order 2-3-4-5-6-1 Valve timing Intake valve Opens (ATDC) 4° ~ -56° Closes (ABDC) 60°…
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Valve stem to valve 0.10mm(0.0039in.) Intake 0.020 ~ 0.050mm(0.0008 ~ 0.0020in.) guide clearance or less 0.13mm(0.0051in.) Exhaust 0.035 ~ 0.065mm(0.0014 ~ 0.0026in.) or less Valve guide Inner diameter Intake 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.) Exhaust 6.000 ~ 6.015mm(2.2362 ~ 2.2368in.) Length Intake 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.)
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No. 2 ring 0.03 ~ 0.07mm(0.0012 ~ 0.0027in.) 0.1mm(0.0039in.) Oil ring 0.06 ~ 0.15mm(0.0024 ~ 0.0059in.) 0.2mm(0.0079in.) End gap No. 1 ring 0.15 ~ 0.30mm(0.0059 ~ 0.0118in.) 0.6mm(0.0236in.) No. 2 ring 0.30 ~ 0.45mm(0.0118 ~ 0.0177in.) 0.7mm(0.0275in.) Oil ring 0.20 ~ 0.70mm(0.0078 ~ 0.0275in.) 0.8mm(0.0315in.) Piston ring O.S.
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Vacuum valve opening 0.98 ~ 4.90 kpa(0.01 ~ 0.05 kg/cm², 0.14 ~ 0.71 pressure psi) Engine coolant temperature sensor Type Thermister type Resistance 20°C (68°F) 2.31 ~ 2.59 kΩ 80°C(176°F) 0.3222 kΩ TIGHTENING TORQUE Item Quantity kgf.m lb-ft Oil seal case bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7…
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Timing belt tensioner bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5 Timing belt tensioner arm bolt 34.3 ~ 53.9 3.5 ~ 5.5 25.3 ~ 39.8 Water pump bolt(8×20) 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9 Water pump bolt(8×25) 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9…
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Timing system Timing belt…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the engine cover. 2. Remove the front right wheel and tire. 3. Remove the right side cover. 4. Remove the drive belt(A), the idler(B) and the tensioner(C). In removing the drive belt, fix a tool in the auto tensioner pulley bolt and turn the bolt counter clockwise. 5.
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Sustain the engine oil pan with a jack. Put a wooden or rubber block between the jack and the engine oil pan. 8. Remove the crankshaft damper pulley(A). 9. Remove the timing belt lower cover(A). 10. Remove the engine support bracket(A).
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After the removal, engine coolant can be drained a little from that point(B) which is a matter of no importance. 11. Remove the timing belt auto tensioner(A). 12. Remove the timing belt(A). Make a direction mark of revolution on the timing belt for reusal. 13.
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14. Remove the crankshaft sprocket. INSTALLATION 1. Install the crankshaft sprocket. 2. Install the tensioner arm assembly(A) and the idler(B). Tightening torque Tensioner arm bolt : 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3~ 39.8lb-ft) Idler pulley bolt : 49.0 ~ 58.8Nm(5.0 ~ 6.0kgf.m, 36.2~ 43.4lb-ft) 3.
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a. When pressing the rod, use a vertical vice certainly. b. There is a high possibility for air to get in the high pressure chamber, when using a horizotal vice. c. Do not apply more load than 400N on the rod. d.
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6. Remove the auto tensioner set-pin. 7. Check the tension of the timing belt. (1) Turn the crankshaft 2 rev. clockwise which makes the No.1 cylinder piston position at TDC. After 5minutes, measure the length of the projected rod. Specification 5 ~ 7mm(0.1969 ~ 0.2756in.) (2) Ensure the locations of the timing marks for each sprocket.
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10. Install the crankshaft damper pulley(A). Tightening torque 166.7 ~ 176.5Nm(17.0 ~ 18.0kgf.m, 123.0 ~ 130.2lb-ft) 11. Install the engine mounting bracket(A). Tightening torque 63.7 ~ 83.4Nm(6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft) 12. Install the timing belt upper cover(A). Tightening torque 9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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13. Install the drive belt tensioner(C). Tightening torque 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft) 14. Install the drive belt idler and the drive belt(A). Tightening torque 34.3 ~ 53.9Nm(3.5 ~ 5.5kgf.m, 25.3 ~ 39.8lb-ft) 15. Install the right side cover. 16.
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3. Replace the tensioner and the idler if grease is leaked from bearings. TIMING BELT 1. Check the belt for oil or dust deposits. Replace, if necessary. Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent. 2.
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Cylinder Head Assembly…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL a. Use fender covers to avoid damaging painted surfaces. b. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it. c. When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket. d.
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5. Remove the fuel inlet hose(A) from the delivery pipe. 6. Disconnect the engine wiring harness connectors. (1) Disconnect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E). (2) Disconnect the bank 1 front/rear O2 sensor connectors(A).
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(4) Disconnect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E). (5) Disconnect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). (6) Disconnect the generator connector(A) and the air conditioning compressor connector(B).
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(7) Disconnect the bank 2 CMP sensor connector(A) and the ECT(Engine Coolant Temperature) sensor connector(B). (8) Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C). (9) Disconnect the bank 1 CMP sensor connector(A). 7. Remove the PCV(Pulge Control Valve) hose(A).
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8. Disconnect the brake vaccume hose(A). 9. Remove the heater hoses. 10. Remove the drive belt(A). 11. Remove the power steering pump.(Refer to ‘ST’ group). 12. Remove the exhaust manifold assembly.(Refer to ‘Intake and exhause system’). 13. Remove the intake manifold assembly.(Refer to ‘Intake and exhause system’). 14.
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18. Remove the camshaft bearing cap(A). 19. Remove the timing chain tensioner(A). 20. Remove the camshaft. 21. Remove the bank 2 timing belt rear cover(A). 22. Remove the bank 1 timing belt rear cover(A).
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23. Remove the CKP sensor connector bracket(A). 24. Remove the cylinder head assembly. (1) Remove the bolts in 2~3 steps as following orders. If the bolts are not removed as the order, the deformation of the head assembly can be occurred. (2) Put the cylinder head assembly on a wooden block after removal from the cylinder block.
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2. Reprocess the valve guide hole for the oversized valve guide newly installed. 3. Using the SST(09221-3F100A/B), insert the valve guide in the upside of the cylinder head assembly. Be aware of the difference in length between the intake and the exhaust valve guides. Specification Intake valve guide: 45.8 ~ 46.2mm(1.8031 ~ 1.8189in.) Exhaust valve guide: 46.8 ~ 47.2mm(1.8425 ~ 1.8583in.)
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Ensure the LH/RH classification of the cylinder head gasket when installing. 2. Tighten the cylinder head bolts with the plain washers in several steps as following order. a. In assembling washers, the marked surface should face upward. b. In installing the cylinder head bolts, apply engine oil on the thread of the bolts and the surface of the washers.
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camshaft. Ensure that the pin will not be installed in the hole for oil feeding. Tightening torque 66.7~78.5Nm(6.8~8.0kgf.m, 49.2~57.9lb-ft) After tightening the CVVT bolts, rotate the CVVT assembly housing counterclockwise by hand to seat the lock pin in the CVVT assembly in good position. Fix the hexagonal part of the camshaft in a vice when tightening the CVVT bolts.
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6. Install the camshaft bearing caps. Tightening torque Bearing cap bolt(A: 6×38) — 10.8~12.7Nm(1.1~1.3kgf.m, 8.0~9.4lb-ft) Bearing cap bolt(B: 8×38) — 20.6~22.5Nm(2.1~2.6kgf.m, 15.2~18.8lb-ft) When installing the bearing caps, check the marks on them as shown below and install them in its proper position.
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7. Using the SST(09214-21000), install the camshaft oil seal. a. Befor installing, apply engine oil. b. The camshaft cap surface should adhere to the cylinder head assembly. c. Do not press an eccentric load. 8. Install the CKP sensor connector bracket(A). 9.
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The length of the bolt(B) is longer than that of the bolt(C). 11. Install the timing belt.(Refer to ‘Timing system’). 12. Check and adjust the valve clearance. 13. Install the cylinder head cover. (1) Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover. (2) Assemble the cylinder head cover in five minites after applying liquid gasket(LOCTITE 5900) on the camshaft cap and packing part.
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a. Do not start engine for thirty minites after assembling the cylinder head cover. b. Do not reuse the cylinder head cover gasket. 14. Install the water temp. control assembly. 15. Install the intake manifold assembly. 16. Install the exhaust mainfold assembly. 17.
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(2) Connect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C). (3) Connect the bank 2 CMP sensor connector(A) and the WTS(Water Temperature Sensor) connector(B). (4) Connect the generator connector(A) and the air conditioning compressor connector(B). (5) Connect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C).
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(6) Connect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E). (7) Connect the injection connectors(A,B,C), the ground lines(D), the condensor connector(E) and the Ignition coil connectors(F). (8) Connect the bank 1 front/rear O2 sensor connectors(A).
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(9) Connect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E). 23. Install the fuel inlet hose(A) from the delivery pipe. 24. Install the upper radiator hose(A) and lower radiator hose(B). 25.
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(2) Connect the breather hose(B) from air cleaner hose. (3) Connect the MAF connector(A). 26. Install the engine cover. 27. Refill engine coolant. DISASSEMBLY Identify MLA(Mechanical Lash Adjuster), valves and valve springs as they are removed so that each item can be reinstalled in its original position.
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(5) Using SST(09222-29000), remove the valve stem seal. Do not reuse the removed valve stem seals. 3. Remove OCV(Oil Control Valve)(A). INSPECTION CYLINDER HEAD 1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
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Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. VALVE AND VALVE SPRING 1. Inspect valve stems and valve guides. (1) Using a caliper gauge, measure the inside diameter of the valve guide. Valve guide inside diameter Intake / Exhaust : 6.000 ~ 6.015mm (2.2362 ~ 2.2368in.) (2) Using a micrometer, measure the outer diameter of the valve stem.
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If the margin thickness is less than the specification, replace the valve. Specification Intake : 1.0mm(0.0394in.) Exhaust : 1.3mm(0.0512.) (4) Check the valve length. Length Intake : 110.1mm(4.3346in) Exhaust : 111.1mm(4.3740in) (5) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
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MLA(Mechanical Lash Adjuster) 1. Inspect MLA. Using a micrometer, measure the MLA outside diameter. MLA O.D. Intake/Exhaust : 29.964 ~ 29.980mm(1.1797 ~ 1.1803in.) 2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head. Tappet bore I.D. Intake/Exhaust : 30.000 ~ 30.025mm(1.1811 ~ 1.1821in.) 3.
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(4) Install the bearing caps with the tightening torque. Do not turn the camshaft. (5) Remove the bearing caps. (6) Measure the plastigage at its widest point. Bearing oil clearance [Standard value] Intake : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) Exhaust : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.) If the oil clearance is greater than the maximum, replace the camshaft.
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If the end play is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head. (3) Remove the camshafts. CVVT ASSEMBLY 1. Inspect CVVT assembly. (1) Fix the CVVT assembly with a vice. Ensure that the cam lobe and journal is not damaged. (2) Check that the CVVT assembly will not turn.
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REASSEMBLY a. Thoroughly clean all parts to be assembled. b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. c. Replace oil seals with new ones. 1. Install valves. (1) Using SST(09222-22001), push in a new valve stem seal with applying engine oil. a.
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(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock. 2. Install MLAs with engine oil applied on its surface. Check that the MLA rotates smoothly by hand.
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a. Do not reuse the OCV when dropped. b. Keep clean the OCV. c. Do not hold the OCV sleeve during servicing. d. When the OCV is installed on the engine, do not move the engine while holding the OCV yoke. e.
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Engine Transaxle Assembly…
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2007 > 2.7L V6 GASOLINE > REMOVAL a. Use fender covers to avoid damaging painted surfaces. b. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. a. Mark all wiring and hoses to avoid misconnection. 1. Remove the engine cover. 2.
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5. Remove the under cover. 6. Drain the engine coolant. 7. Remove the upper radiator hose(A) and lower radiator hose(B). 8. Remove the transaxle oil cooler hoses(A/T vehicles only). 9. Remove the fuel inlet hose(A) from the delivery pipe. 10. Disconnect the engine wiring harness connectors.
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(1) Disconnect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E). (2) Disconnect the bank 1 front/rear O2 sensor connectors(A). (3) Disconnect the injection connectors(A,B,C), the ground lines(D), the condenser connector(E) and the Ignition coil connectors(F).
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(5) Disconnect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). (6) Remove the cooling fan relay cable(A). (7) Disconnect the generator connector(A) and the air conditioning compressor connector(B). (8) Disconnect the bank 2 CMP sensor connector(A) and the WTS(Water Temperature Sensor) connector(B). (9) Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C).
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(10) Disconnect the bank 1 CMP sensor connector(A). 11. Disconnect engine wiring. (1) Remove the engine room fuse and relay box cover(A). (2) Disconnect the PCM connectors(B). (3) Disconnect the FAM connectors(C)(Refer to HA group). (4) Unscrew the FAM mounting bolts(D-3EA) and take the FAM(E) out of the splash shield(F). (5) Disconnect the connector(G) from the splash shield(B).
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12. Remove the heater hoses. 13. Disconnect the brake vaccume hose(A). 14. After draining or gathering power steering fluid, disconnect the power steering hose(A). 15. Remove the radiator grille upper cover(A) for convenience sake. 16. Disconnect the power steering return hose. 17.
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The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of the radiator support upper member assembly. 18. Drain engine oil. 19. Remove the brake caliper.(Refer to DS group). 20. Disconnect the air conditioning compressor hoses.(Refer to HA group). 21.
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support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly. 27. Remove the engine mounting bracket(A) and the ground(B). 28. Remove the transaxle insulator mounting bolt(A). Remove the ECM(Electronic Controlled Mounting) nuts and the solenoid valve connector for A/T vehicles. 29.
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INSTALLATION Installation is in the reverse order of removal. Perform the following : a. Adjust the shift cable. b. Refill the engine with engine oil. c. Refill the transaxle with fluid. d. Refill the radiator with engine coolant. e. Bleed air from the cooling system with the heater valve open. f.
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Cylinder Block…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the drive plate(A). 2. Remove the rear plate(A). 3. Remove timing belt. 4. Remove intake manifold. 5. Remove exhaust manifold. 6. Remove generator from engine.(Refer to ‘ST’ group). 7. Remove power steering pump from engine.(Refer to ‘HA’ group). 8.
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9.8 ~ 11.8Nm(1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 10. Install the drive plate(A). Tightening torque 71.6 ~ 75.5Nm(7.3 ~ 7.7kgf.m, 52.8 ~ 55.7lb-ft) DISASSEMBLY 1. Remove the power steering pump bracket(A) and the knock sensor(B). 2. Remove the air conditioning compressor bracket(A).
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3. Remove the lower oil pan(A). 4. Remove the oil screen(A). 5. Remove the upper oil pan(A). When removing the oil pan, use the SST(09215-3C000) not to damage the contacting surface of the oil pan.
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6. Check the connecting rod side clearance. 7. Check the connecting rod bearing oil clearance. 8. Remove the piston and connecting rod assemblies. a. Keep the bearings the connecting rods and the caps together. b. Arrange the piston and connecting rod assemblies in the correct order. 9.
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14. Remove and arrange the main bearings and thrust bearings in the correct order. 15. Remove the CKP sensor(A). 16. Check the free play between a piston and a piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and the piston pin as a set.
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Arrange the piston rings in the correct order only. 18. Disconnect the connecting rod from the piston. Using a press, remove the piston pin from the piston. (Press-in load : 2451.7 ~ 12258.3N(250 ~ 1250kg, 551.2 ~ 2755.81lb) INSPECTION CONNECTING ROD AND CRANKSHAFT 1.
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(9) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.
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51.012 ~ 51.018mm (2.0083 ~ 2.0086in.) CRANKSHAFT PIN MARK LOCATION DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT CLASS MARK OUTSIDE DIAMETER OF PIN 47.994 ~ 48.000mm 1 or A (1.8895 ~ 1.8898in.) 47.988 ~ 47.994mm 2 or B (1.8893 ~ 1.8895in.) 47.982 ~ 47.988mm 3 or C (1.8891 ~ 1.8893in.)
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(0.0588 ~ 0.0589in.) 1.491 ~ 1.494mm GREEN (0.0587 ~ 0.0588in.) 1.488 ~ 1.491mm YELLOW (0.0586 ~ 0.0587in) (11) Select the proper connecting rod bearing from the table below. CONNECTING ROD IDENTIFICATION MARK 0(A) 1(B) 2(C) I(A) (YELLOW) (GREEN) CRANKSHAFT II(B) INDENTIFICATION MARK (GREEN) (BLACK)
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(6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.
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DISCRIMINATION OF CYLINDER BLOCK CLASS MARK INSIDE DIAMETER 66.000 ~ 66.006mm (2.5984 ~ 2.5987in.) 66.006 ~ 66.012mm (2.5987 ~ 2.5989in.) 66.012 ~ 66.018mm (2.5989 ~ 2.5991in.) CRANKSHAFT JOURNAL MARK LOCATION DISCRIMINATION OF CRANKSHAFT DISCRIMINATION OF CRANKSHAFT CLASS MARK OUTSIDE DIAMETER OF JOURNAL 61.994 ~ 62.000mm (2.4407 ~ 2.4409in.) 61.988 ~ 61.994mm…
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CLASS MARK THICKNESS OF BEARING 2.007 ~ 2.010mm BLUE (0.0790 ~ 0.0791in.) 2.004 ~ 2.007mm BLACK (0.0789 ~ 0.0790in.) 2.001 ~ 2.004mm (0.0788 ~ 0.0789in.) 1.998 ~ 2.001mm GREEN (0.0787 ~ 0.0788in.) 1.995 ~ 1.998mm YELLOW (0.0785 ~ 0.0787in.) SELECTION TABLE CRANKSHAFT BORE IDENTIFICATION MARK a(A) b(B)
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CYLINDER BLOCK 1. Remove gasket materials. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.
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6. Check the cylinder bore size code(A) on the cylinder block. Class Size code Cylinder bore inner diameter 86.70 ~ 86.71mm (3.4134 ~ 3.4138in.) 86.71 ~ 86.72mm (3.4138 ~ 3.4142in.) 86.72 ~ 86.73mm (3.4142 ~ 3.4146in.) 7. Check the piston size code(A) on the piston top face.
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Class Size code Piston outer diameter 86.67 ~ 86.68mm (3.4122 ~ 3.4126in.) 86.68 ~ 86.69mm (3.4126 ~ 3.4130in.) 86.69 ~ 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.
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Standard diameter 86.67 ~ 87.00(3.4122 ~ 3.4252in.) 3. Calculate the difference between the cylinder bore inner diameter and the piston outer diameter. Piston-to-cylinder clearance 0.02 ~ 0.04mm(0.0008 ~ 0.0016in.) 4. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between a new piston ring and the ring groove. Piston ring side clearance Standard No.1 : 0.04 ~ 0.08mm (0.0016 ~ 0.0031in.)
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No.1 : 0.6mm (0.0236in.) No.2 : 0.7mm (0.0275in.) Oil ring : 0.8mm (0.0315in.) PISTON PINS 1. Measure the outer diameter of the piston pin. Piston pin outerdiameter 21.001 ~ 21.007mm (0.8268 ~ 0.8270in.) 2. Measure the piston pin-to-piston clearance. Piston pin-to-piston clearance 0.007 ~ 0.022mm (0.0003 ~ 0.0009in.) 3.
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Piston pin-to-connecting rod interference -0.033 ~ -0.016mm (-0.0013 ~ -0.0006in.) REASSEMBLY a. Thoroughly clean all parts before reassembling. b. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. c. Replace all gaskets, O-rings and oil seals with new parts. 1.
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When reassembling the connecting rods and the caps, ensure the front marks on them. 4. Install the CKP sensor(A). Tightening torque 6.9 ~ 9.8Nm(0.7 ~ 1.0kgf.m, 5.1 ~ 7.2lb-ft) 5. Install main bearings. Upper bearings have the oil grooves of the oil holes; Lower bearings do not. (1) Aligning the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings(A).
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(2) Aligning the bearing claw with the claw groove of the main bearing cap, push in the 4 lower bearings(B) on the bearing caps(A). 6. Install thrust bearings. Install the 2 thrust bearings(A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
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M8 : 15.7Nm(1.6 kgf.m, 11.6lb-ft) + 90° M10 : 29.4Nm(3.0 kgf.m, 21.7lb-ft)+ 90° a. Use new main bearing cap bolt with engine oil applied. b. If any of the bearing cap bolts are broken or deformed, replace it. c. Washers have their direction(Up/Down) d.
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19.6Nm (2.0kgf.m, 14.46lb-ft) + 90° a. Always use new connecting rod bolts. b. Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore. c. Use SST(09221-4A000), install connecting rod bearing cap bolts. 12.
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(1) Make clean the sealing face before assembling two parts. a. Remove harmful foreign materials on the sealing face before applying sealant b. Apply sealant to the inner threads of the bolt holes. (2) Assembling rear oil seal case, the liquid sealant TB1217H should be applied to the rear oil seal case. The part must be assembled within 5 minutes after sealant was applied.
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a. Clean the sealing face before assembling two parts. b. Remove harmful foreign materials on the sealing face before applying sealant. c. When applying sealant gasket, sealant must not protrude into the inside of oil pan. d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. (3) Install upper oil pan.
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Uniformly tighten the bolts in several passes. Tightening torque 9.8 ~ 11.8Nm (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft) 18. Install the air conditioning compressor bracket(A). (Refer to ‘HA’ group) 19. Install the power steering pump bracket(A) and the knock sensor(B). Tightening torque 18.6 ~ 23.5Nm (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) a.
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Cooling system…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL WATER PUMP 1. Drain the engine coolant. System is under high pressure when the engine is hot. To avoid danger of releasing scalding engine coolant, remove the cap only when the engine is cool. 2.
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4. Disconnect the ECT(Engine Coolant Temperature) sensor connector. 5. Remove the coolant hose related to the heater hoses and the ECT(Engine Coolant Temperature) system. 6. Remove wiring protector. 7. Remove water temperature control assembly(A) and the gaskets(B). 8. Remove the water pipe(A). THERMOSTAT Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
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RADIATOR 1. Drain the engine coolant. 2. Remove the radiator grille upper cover(A). 3. Remove the radiator support upper member assembly(A) for convenience sake. The bottom side bolt(A) which can be seen after removing the under cover should be loosened for removal of the radiator support upper member assembly.
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4. Remove the radiator upper and the lower hoses(A). 5. Disconnect transaxle oil cooler hoses(A).(Refer to TR group) 6. Disconnect the radiator fan connectors(A,B).
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7. Remove the radiator bracket(A, B) and the bleeder hose(C). 8. Separate the condenser from the radiator assembly by removing the bolts. 9. Remove the radiator assembly. 10. Remove the radiator cooling fan. INSTALLATION WATER PUMP 1. Install the water pump(A) and a new gasket(B) with the bolts. Tightening torque 14.7 ~ 21.6Nm (1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)
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Clean the contacting face before assembling. 2. Install the timing belt. 3. Install drive belt(A). 4. Fill with engine coolant. 5. Start engine and check for leaks. 6. Recheck engine coolant level. WATER TEMPERATURE CONTROL ASSEMBLY 1. Install the water pipe(A). Tightening torque 16.7 ~ 19.6Nm (1.7 ~ 2.0kgf.m, 12.3 ~ 14.5lb-ft) 2.
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29.4 ~ 41.2Nm(3.0 ~ 4.2kgf.m, 21.7 ~ 30.4lb-ft Use new O-rings and wet them with water or coolant when reassembling. 3. Install the wiring protector. 4. Connect the heater hose and ECT hose. 5. Connect the ECT sensor connector. 6. Connect the radiator upper and the lower hose(A). 7.
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2. Install the coolant inlet pitting(A). Tightening torque 16.66 ~ 19.60Nm (1.7 ~ 2.0kgf.m, 12.30 ~ 14.47lb-ft) 3. Fill with engine coolant. 4. Start engine and check for leaks. RADIATOR 1. Install the radiator fan(A) to the radiator. Tightening torque 4.9 ~ 7.8Nm (0.5 ~ 0.8kgf.m, 3.6 ~ 5.8lb-ft) 2.
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5. Connect the radiator fan connectors(A,B) 6. Install the transaxle oil cooler hoses(A).(Refer to TR group)
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7. Install the radiator upper(A) and lower hoses(B). 8. Install the radiator support upper member assembly(A). 9. Install the radiator grille upper cover(A). 10. Fill with engine coolant. 11. Start engine and check for leaks. 12. Recheck engine coolant level. INSPECTION WATER PUMP 1.
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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.
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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.
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Lubrication system…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL Oil pump case 1. Drain engine oil. 2. Remove the front right wheel and tire. 3. Remove the front right side cover. 4. Remove the front muffler. 5. Remove the generator. 6. Remove the timing belt. 7.
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10. Remove the upper oil pan, using the SST(09215-3C000)(A). Be careful not to damage the contact surfaces of upper oil pan and lower oil pan. 11. Remove the oil pump case(A). 12. After removing the plug(A), remove the relief spring(B) and the velief plunger(C). REPLACEMENT OIL AND FILTER a.
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c. In order to preserve environment, used oil or used oil filter must be disposed only at designated disposal sites. 1. Park the car on a level ground. Start the engine and let it warm up. 2. Turn the engine off. 3.
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Tightening torque 39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft) 2. Install oil pump case. (1) Using a gasket scraper, remove all the old packing material from the gasket surfaces. (2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan. The part must be assembled within 5 minutes after the sealant was applied.
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In the installation of the oil pump, always use a new o-ring(B). 3. Using the SST(09214~33000), install the oil pump case oil seal. 4. Install the upper oil pan. (1) Using a gasket scraper, remove all the old packing material from the gasket surfaces. (2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on the oil pan.
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d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. e. After assembly, wait at least 30 minutes before filling the engine with oil. (3) Fix the oil pan and tighten the bolts in several steps uniformly. Tightening torque Bolts 1~15 : 18.6 ~ 23.5Nm(1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft) Bolts 16,17 : 4.9 ~ 6.9Nm(0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
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a. Make clean the sealing face before assembling two parts. b. Remove harmful foreign materials on the sealing face before applying sealant. c. When applying sealant gasket, sealant must not be protrude into the inside of oil pan. d. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes. e.
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Always use a new O-ring. 8. Install the timing belt, the generator and the front muffler. 9. Install the front right side cover and the wheel and tire. 10. Fill with engine coolant. 11. Start engine and check for leaks. 12.
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For best performance and maximum protection of all types of operation, select only those lubricants which : a. Satisfy the requirement of the API classification. b. Have proper SAE grade number for expected ambient temperature range. Lubricants that do not have both an SAE grade number and API service classification on the container should not be used.
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2. Check the continuity between the terminal and the body when its hole is pushed by a fine rod(A). If there is continuity with pressed, replace the switch. 3. If there is no continuity when the pressure 49.3kpa (0.5kg/cm², 7.11psi) is applied through the oil hole, the switch is operating properly.
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Intake Exhaust system…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL INTAKE MANIFOLD ASSEMBLY 1. Remove the engine cover. 2. Remove the intake air hose and air cleaner assembly. (1) Disconnect the MAF connector(A). (2) Disconnect the breather hose(B) from air cleaner hose. (3) Remove the intake air hose and air cleaner assembly(C). 3.
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(4) Disconnect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E). (5) Disconnect the MAPS(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C). (6) Disconnect the generator connector(A) and the air conditioning compressor connector(B).
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(7) Disconnect the bank 2 CMP sensor connector(A) and the ECT(Engine Coolant Temperature) sensor connector(B). (8) Disconnect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C). (9) Disconnect the bank 1 CMP sensor connector(A). 4. Remove the PCV(Pulge Control Valve) hose(A).
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5. Remove the ETC(Electric Throttle Control) bracket(A) and the cooling hoses(B). 6. Disconnect the brake vaccume hose(A). 7. Remove the surge tank mounting bracket(A). 8. Remove the surge tank(A).
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9. Remove the delivery pipe assembly(A). 10. Remove the intake manifold assembly(A). EXHAUST MANIFOLD ASSEMBLY 1. Remove the under cover. 2. Remove the front muffler(A).
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3. Disconnect the oxygen sensor connectors(A). 4. Remove the oil level gauge. 5. Remove the heat protector(A). 6. Remove the exhaust manifold assembly. INSTALLATION INTAKE MANIFOLD ASSEMBLY…
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1. Install the intake manifold assembly with a new gasket to a cylinder head assembly. Tighten the bolts in two steps. Tightening torque Step 1(a~h): 3.9~5.9Nm(0.4~0.6kgf.m, 2.9~4.3lb-ft) Step 2(1~8): 18.6~23.5Nm(1.9~2.4kgf.m, 13.7~17.4lb-ft) When installing the gasket on the cylinder head, check the indentification marks(LH/RH) not to be installed wrong.
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Tightening torque 39.2~58.8Nm(4.0~6.0kgf.m, 28.9~43.4lb-ft) 4. Connect the oxygen sensor connector. 5. Install the under cover.
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CHAPTER 3: Engine Electrical System…
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General information…
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2007 > 2.7L V6 GASOLINE > THE MICRO 570 ANALYZER The MICRO 570 Analyzer provides the ability to test the charging and starting systems, including the battery, starter and generator. Because of the possibility of personal injury, always use extreme caution and appropriate eye protection when working with batteries.
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2. The tester will ask if the battery is connected «IN A VEHICLE» or «OUT OF A VEHICLE». Make your selection by pressing the arrow buttons; then press ENTER. 3. Choose either CCA or CCP and press the ENTER button. a.
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The battery ratings (CCA) displayed on the tester must be identical to the ratings marked on battery label. 6. To conduct starter test, press ENTER. BATTERY TEST RESULTS RESULT ON PRINTER REMEDY Good battery No action is required Battery is in a good state Good recharge Recharge the battery and use Battery is not charged properly…
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2. After pressing ENTER key, start the engine. 3. Cranking voltage and starter test results will be displayed on the screen. Take a relevant action according to the test results by referring to the starter test results as given below. 4.
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2. ENTER button is pressed, the tester displays the actual voltage of generator. Press ENTER to test the charging system. 3. The MICRO 570 will prompt you to rev the engine until the rev detected. It will then collect the data. 4.
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6. The MICRO 570 will detect the amount of ripple from the charging system to the battery. Excessive ripple usually means the stator is damaged or that one or more generator diodes have failed. 7. The MICRO 570 will prompt you to turn on accessary loads. It will then test at idle and prompt you to rev the engine.
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CHARGING SYSTEM TEST RESULTS RESULT ON PRINTER REMEDY Charging system normal/Diode ripple normal Charging system is normal Generator does not supply charging current to battery No charging voltage => Check belts, connection between generator and battery Replace belts or cable or generator as necessary Generator does not supply charging current to battery and electrical Low charging voltage load to system fully…
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2007 > 2.7L V6 GASOLINE > SPECIAL SERVICE TOOL Tool (Number and name) Illustration Alternator pulley remover wrench Removal and installation of alternator (09373-27000) pulley REFERENCE SERVICE TOOLS Tool (Number and name) Illustration a. Check the battery condition Micro-570 b. Check the charging and starting Battery checker system…
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2007 > 2.7L V6 GASOLINE > TROUBLE SHOOTING IGNITION SYSTEM Symptom Suspect area Remedy Engine will not start or Ignition lock switch Inspect ignition lock switch, or replace as required is hard to start Ignition coil Inspect ignition coil, or replace as required (Cranks OK) Spark plugs Inspect spark plugs, or replace as required…
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Fuse blown Replace fuse Starter motor faulty Replace Ignition switch faulty Replace Engine cranks slowly Battery charge low Charge or replace battery Battery cables loose, corroded or Repair or replace cables worn out Starter motor faulty Replace Starter keeps running Starter motor Replace Ignition switch…
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2007 > 2.7L V6 GASOLINE > SPECIFICATION IGNITION SYSTEM Items Specification 0.715 ± 0.015 Ω Primary resistance Ignition coil Secondary resistance Spark plugs ILFR5B11 Plugs Gap 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in) STARTING SYSTEM Items Specification Rated voltage 12 V, 1.2 kW No.
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Ignition System…
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2007 > 2.7L V6 GASOLINE > DESCRITION Ignition timing is controlled by the electronic control ignition timing system. The standard reference ignition timing data for the engine operating conditions are preprogrammed in the memory of the ECM (Engine Control Module). The engine operating conditions (speed, load, warm-up condition, etc.) are detected by the various sensors.
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2007 > 2.7L V6 GASOLINE > REMOVAL IGNITION COIL 1. Remove the engine cover. 2. Remove the ignition coil (A). 3. Remove the ignition coil. 4. Installation is the reverse of removal. REPLACEMENT SPARK PLUG 1. Remove the ignition coil connector(A). 2.
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a. [U2.7] L nleaded : ILFR5B11 Leaded : LFR5A ON-VEHICLE INSPECTION SPARK TEST 1. Remove the ignition coil connector(A). Disconnect the iguition coil connector while pulling up tre connector lock. 2. Remove the ignition coil. 3. Using a spark plug socket, remove the spark plug. 4.
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INSPECT SPARK PLUG 1. Inspect the electrodes(A) an ceramic insulator(B). INSPECTION OF ELECTRODES Condition Dark deposits White deposits a. Fuel mixture too lean a. Fuel mixture too rich Description b. Advanced ignition timing b. Low air intake c. Insufficient plug tightening torque 2.
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INSPECT IGNITION COIL 1. Measure the primary coil resistance between terminals (+) and (-). Standard : 0.0715 ± 0.015Ω Mesure the resistance between the terminals No.1 and No.3.
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Charging System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION The charging system included a battery, an alternator with a built-in regulator, and the charging indicator light and wire. The Alternator has built-in diodes, each rectifying AC current to DC current. Therefore, DC current appears at alternator «B» terminal. In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
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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.
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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»…
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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.
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6. Connect a DC ammeter (0 to 150A) in series between the «B» terminal and the disconnected output wire. Connect the (-) lead wire of the ammeter to the disconnected output wire. 7. Attach the engine tachometer and connect the battery ground cable. TEST 1.
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Alternator…
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2007 > 2.7L V6 GASOLINE > COMPONENT…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the battery negative terminal first, then the positive terminal. 2. Disconnect the alternator connector, and remove the cable from alternator «B» terminal. 3. Remove the drive belt. 4. Pull out the through bolt and then remove the alternator(A). 5.
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5. Remove the nut, pulley(A) and spacer. 6. Loosen the 4 through bolts(A). 7. Disconnect the rotor(A) and cover(B). 8. Reassembly is the reverse order of disassembly. INSPECTION INSPECT ROTOR 1. Check that there is continuity between the slip rings (A).
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2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C). 3. If the rotor fails either continuity check, replace the alternator. INSPECT STATOR 1. Check that there is continuity between each pair of leads (A). 2.
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Battery…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell caps. 2. Water never needs to be added to the maintenance-free battery. 3. The battery is completely sealed, except for small vent holes in the cover.
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2007 > 2.7L V6 GASOLINE > INSPECTION BATTERY DIAGNOSTIC TEST (1) CHECKING FLOW LOAD TEST 1. Perform the following steps to complete the load test procedure for maintenance free batteries. 2. Connect the load tester clamps to the terminals and proceed with the test as follow:…
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(1) If the battery has been on charge, remove the surface charge by connect a 300ampere load for 15 seconds. (2) Connect the voltmeter and apply the specified load. (3) Read the voltage after the load has been applied for 15 seconds. (4) Disconnect the load.
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8. Clean the inside surface of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and broken terminal clamps. 9. Install the battery in the vehicle. 10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops of the posts.
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Starting System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/T), ignition lock switch, connection wires and the battery cable. When the ignition key is turned to the start position, current flows and energizes the starter motor’s solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
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2007 > 2.7L V6 GASOLINE > STARTER CIRCUIT TROUBLESHOOTING The battery must be in good condition and fully charged. 1. Remove the fuel pump relay(A) from the fuse box. 2. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to «START» If the starter normally cranks the engine, starting system is OK.
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4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly. To avoid damaging the starter, do not leave the battery connected for more than 10 seconds. FREE RUNNING TEST 1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows.
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Starter…
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2007 > 2.7L V6 GASOLINE > COMPONENT…
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2007 > 2.7L V6 GASOLINE > REMOVAL STATATER 1. Disconnect the battery negative cable. 2. Disconnect the starter cable (A) from the B terminal (B) on the solenoid (C), then disconnect the connector (D) from the S terminal (E). 3. Remove the 2 bolts holding the starter, then remove the starter. 4.
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4. Remove the brush holder assembly (A), yoke (b) and armature (C). 5. Remove the shield (A) and packing (B). 6. Remove the lever plate (A) and lever packing (B). 7. Disconnect the planet gear (A).
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8. Disconnect the planet shaft assembly (A) and lever (B). 9. Press the stop ring (A) using a socket (B). 10. After removing the stopper (A) using stopper pliers (B). 11. Disconnect the stop ring (A), overrunning clutch (B), internal gear (C) and planet shaft (D). 12.
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INSPECTION ARMATURE INSPECTION AND TEST 1. Remove the starter. 2. Disassemble the starter as shown at the beginning of this procedure. 3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
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6. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or v-shaped (D).
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STARTER BRUSH HOLDER TEST 1. Check that there is no continuity between the (+) brush holder (A) and (-) brush holder (B). If there is no continuity, replace the brush holder assembly. 2. Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its holder, and release the spring to hold it there.
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INSPECT OVERRUNNING CLUTCH 1. Slide the overrunning clutch along the shaft. Replace it if does not slide smoothly. 2. Rotate the overrunning clutch both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it locks in both directions, replace it.
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Starter Relay…
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2007 > 2.7L V6 GASOLINE > INSPECTION 1. Remove the fuse box cover. 2. Remove the starter relay. 3. Using an ohmmeter, check that there is continuity between each terminal. Terminal Continuity 30 — 87 85 — 86 4. Apply 12V to terminal 85 and ground to terminal 86. Check for continuity between terminals 30 and 87.
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CHAPTER 4: Emission Control System…
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2007 > 2.7L V6 GASOLINE > SCHEMATIC DIAGRAM…
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General Information…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Components Function Remarks Crankcase Emission System HC reduction Variable flow rate type a. Positive Crankcase Ventilation (PCV) valve Evaporative Emission System HC reduction a. Evaporative emission canister HC reduction Duty control solenoid valve b.
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2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION Purge Control Solenoid Valve (PCSV) Positive Crankcase Ventilation (PCV) Valve Canister Catalytic Converter (Bank 1)
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Catalytic Converter (Bank 2)
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2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Symptom Suspect area Remedy Vacuum hose disconnected or damaged Repair or replace Engine will not start or hard to Malfunction of the Purge Control Solenoid start Repair or replace Valve Vacuum hose disconnected or damaged Repair or replace Malfunction of the PCV valve Replace…
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2007 > 2.7L V6 GASOLINE > SPECIFICATIONS ▷ Specification Item Specification 14.0 ~ 18.0 Ω [20°C (68°F)] Coil Resistance (Ω) TIGHTENING TORQUES Item N·m kgf·m lbf·m Positive Crankcase Ventilation Valve 8.0 ~ 12.0 0.8 ~ 1.2 6.0 ~ 8.0…
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Crankcase Emission Control System…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > INSPECTION 1. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from the rocker cover and reconnect it to the ventilation hose. 2. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold vacuum can be felt.
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Positive Crankcase Ventilation (PVC) Valve…
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2007 > 2.7L V6 GASOLINE > OPERATION Engine condition Not running Engine condition Idling or decelerating PCV valve Not operating PCV valve Fully operating Vacuum passage Restricted Vacuum passage Small Engine condition Normal operation Engine condition Accelerating and high load PCV valve Properly operating PCV valve…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the vacuum hose (A). 2. Remove the PCV Valve (B). INSTALLATION Install the PCV valve and tighten to the specified torque. PCV Valve installation : 7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m, 5.8 ~ 8.7lbf·ft) INSPECTION 1.
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Evaporative Emission Control System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION…
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2007 > 2.7L V6 GASOLINE > INSPECTION 1. Disconnect the vacuum hose from the throttle body, and connect a vacuum pump to the vacuum hose. 2. Check the following points when the engine is cold [engine coolant temperature 60°C(140°F) or below] and when it is warm [engine coolant temperature 80°C(176°F) or higher].
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Canister…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the vacuum hoses (A,B). 2. Remove the canister assembly (A) with unscrewing the two mounting bolts (B). 3. Open the canister upper cover (A) with unfastening the four bolts (B) and remove the canister (C) from the canister lower cover (D).
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INSTALLATION Install the canister according to the reverse order of «REMOVAL» procedure. INSPECTION 1. Look for loose connections, sharp bends or damage to the fuel vapor lines. 2. Look for distortion, cracks or fuel damage. 3. After removing the canister, inspect for cracks, damage or saturated canister.
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Purge Control Solenoid Valve (PCSV)
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2007 > 2.7L V6 GASOLINE > INSPECTION When disconnecting the vacuum hose, make an identification mark on it so that it can be reconnected to its original position. 1. Disconnect the vacuum hose from the solenoid valve. 2. Detach the harness connector. 3.
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect PCSV connector. 3. Measure resistance between PCSV terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Fuel Filler cap…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION…
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Exhaust Emission Control System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system. These items have been integrated into a highly effective system which controls exhaust emissions while maintaining good driveability and fuel economy. AIR/FUEL MIXTURE CONTROL SYSTEM [MULTIPORT FUEL INJECTION (MFI) SYSTEM] This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three way catalyst.
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CVVT (Continuously Variable Valve Timing) System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION The CVVT (Continuously Variable Valve Timing) which is installed on the exhaust camshaft controls intake valve open and close timing in order to improve engine performance. The intake valve timing is optimized by CVVT system depending on engine rpm. This CVVT system improves fuel efficiency and reduces NOx emissions at all levels of engine speed, vehicle speed, and engine load by EGR effect because of valve over-lap optimization.
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1. The above figure shows the relative operation structures of the housing vane to the rotor vane. 2. If the CVVT is held a certain control angle, to hold this state, oil is replenished as much as oil leaks from the oil pump.
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CHAPTER 5: Fuel System…
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General Information…
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2007 > 2.7L V6 GASOLINE > SPECIAL SERVICE TOOLS Tool Illustration Application (Number and name) 09353-24100 Measuring the fuel line pressure Fuel Pressure Gauge 09353-38000 Connection between the delivery pipe and Fuel Pressure Gauge fuel feed line Adapter 09353-24000 Connection between Fuel Pressure Gauge Fuel Pressure Gauge (09353-24100) and Fuel Pressure Gauge Connector…
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2007 > 2.7L V6 GASOLINE > BASIC TROUBLESHOOTING BASIC TROUBLESHOOTING GUIDE CUSTOMER PROBLEM ANALYSIS SHEET…
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BASIC INSPECTION PROCEDURE The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient temperature (20°C, 68°F), unless stated otherwise. The measured resistance in except for ambient temperature (20°C, 68°F) is reference value. Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing.
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during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly make out a «CUSTOMER PROBLEM ANALYSIS SHEET» and recreate (simulate) the environment and condition which occurred when the vehicle was having the issue. 1.
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1. Handling of Connector a. Never pull on the wiring harness when disconnecting connectors. b. When removing the connector with a lock, press or pull locking lever. c. Listen for a click when locking connectors. This sound indicates that they are securely locked. d.
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e. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. a. Use a fine wire to prevent damage to the terminal. b. Do not damage the terminal when inserting the tester lead. 2. Checking Point for Connector a.
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Never use sand paper when polishing the contact points, otherwise the contact point may be damaged. b. In case of abnormal contact pressure, replace the female terminal. WIRE HARNESS INSPECTION PROCEDURE 1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly. 2.
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b. Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG. 3]. In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).
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2. Continuity Check Method (with Chassis Ground) Lightly shake the wire harness above and below, or from side to side when measuring the resistance. Specification (Resistance) 1Ω or less → Short to Ground Circuit 1MΩ or Higher → Normal Circuit a.
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MAIN SYMPTOM DIAGNOSTIC PROCEDURE ALSO CHECK FOR Unable to start a. Test the battery (Engine does not turn b. Test the starter over) c. Inhibitor switch (A/T) or clutch start switch (M/T) a. DTC a. Test the battery Unable to start b.
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b. Check the fuel pressure d. Contaminated fuel c. Check the injector e. Weak ignition spark d. Test the exhaust system for a possible restriction e. Check the ECTS and circuit a. Test the canister close valve b. Inspect the fuel filler hose/pipe Hard to refuel a.
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2007 > 2.7L V6 GASOLINE > SPECIFICATIONS FUEL DELIVERY SYSTEM Items Specification Fuel Tank Capacity 80 lit. (21.1 U.S.gal., 17.6 Imp.gal.) Fuel Filter (built in Fuel Pump Type High pressure type assembly) Fuel Pressure Regulator (built in Regulated Fuel 375 ~ 385 kPa(3.82 ~ 3.92 kgf/cm², 54.3 ~ 55.8 psi) Fuel Pump assembly) Pressure Type…
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3.51 1.47 0.67 0.33 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAPS) ▷ Type: Piezo-resistive pressure type ▷ Specification Pressure (kPa) Output Voltage (V) 20.0kPa 0.79 46.66kPa 1.84 101.32kPa ENGINE COOLANT TEMPERATURE SENSOR (ECTS) ▷ Type: Thermistor type ▷ Specification Temperature Resistance (kΩ) °C °F 48.14…
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Item Sensor Resistance (kΩ) TPS1 4.0 ~ 6.0 [20°C (68°F)] TPS2 2.7 ~ 4.1 [20°C (68°F)] ACCELERATOR POSITION SENSOR (APS) ▷ Type: Variable resistor type ▷ Specification (When reference voltage = 5.0V) Output Voltage (V) Accelerator Position APS1 APS2 0.70 ~ 0.80 0.29 ~ 0.46 W.O.T 3.85 ~ 4.35…
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▷ Specification Item Specification Capacitance (pF) 950 ~ 1,350pF CVVT OIL TEMPERATURE SENSOR (OTS) ▷ Type: Thermistor type ▷ Specification Temperature Resistance (kΩ) °C °F 52.0 16.5 2.45 1.10 0.544 0.290 0.164 0.099 ACTUATORS INJECTOR ▷ Number: 6 ▷ Specification Item Specification Coil Resistance (Ω)
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Coil Resistance (Ω) 6.7 ~ 7.7 [20°C (68°F)] CVVT OIL CONTROL VALVE (OCV) [BANK 2] ▷ Specification Item Specification Coil Resistance (Ω) 6.7 ~ 7.7 [20°C (68°F)] ETC MOTOR ▷ Specification Item Specification Coil Resistance (Ω) 1.275 ~ 1.725 [20°C (68°F)] IGNITION COIL ▷…
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Heated oxygen sensor (Bank 2 / Sensor 2) installation 3.5 ~ 4.5 34.3 ~ 44.1 25.3 ~ 32.6 Ignition coil installation bolt 1.0 ~ 1.2 9.8 ~ 11.8 7.2 ~ 8.7 Knock sensor [Bank 1] installation 1.9 ~ 2.4 18.6 ~ 23.5 13.7 ~ 17.4 Knock sensor [Bank 2] installation 1.9 ~ 2.4…
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Engine Control System…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Engine is hard to start or does not start at all. 2. Unstable idle. 3. Poor driveability If any of the above conditions are noted, first perform a routine diagnosis that includes basic engine checks (ignition system malfunction, incorrect engine adjustment, etc.).
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Faults with the following items will illuminate the MIL a. Heated oxygen sensor (HO2S) b. Mass Air Flow sensor (MAFS) c. Throttle position sensor (TPS) d. Engine coolant temperature sensor (ECTS) e. Idle speed control actuator (ISCA) f. Injectors g. ECM Refer to «INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES (DTC)»…
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detected. 4. A Diagnostic Trouble Code(DTC) will automatically erase from ECM memory if the same malfunction is not detected for 40 driving cycles. a. A «warm-up cycle» means sufficient vehicle operation such that the coolant temperature has risen by at least 40 degrees Fahrenheit from engine starting and reaches a minimum temperature of 160 degress Fahrenheit.
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2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION 2. Mass Air Flow Sensor (MAFS) 1. PCM (Powertrain Control Module) 3. Intake Air Temperature Sensor (IATS)
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4. Manifold Absolute Pressure Sensor (MAPS) 5. Engine Coolant Temperature Sensor (ECTS) 17. ETC Module [Throttle Position Sensor (TPS) + ETC 7. Camshaft Position Sensor (CMPS) [Bank2] Motor] 6. Camshaft Position Sensor (CMPS) [Bank 1] 8. Crankshaft Position Sensor (CKPS) 9.
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13. Knock Sensor (KS) [Bank 1] 15. Injector 14. Knock Sensor (KS) [Bank 2] 26. Ignition Coil 18. CVVT Oil Control Valve (OCV) [Bank 1] 16. Accelerator Position Sensor (APS) 19. CVVT Oil Control Valve (OCV) [Bank 2] 20. CVVT Oil Temperature Sensor (OTS) 22.
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23. Variable Intake Solenoid (VIS) #2 Valve (Intake 24. Fuel Pump Relay Manifold Side) 25. Main Relay 27. Wheel Speed Sensor (WSS) 28. Vehicle Speed Sensor (VSS) 31. A/C Pressure Transducer (APT)
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Engine Control Module (ECM)
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2007 > 2.7L V6 GASOLINE > CIRCUIT DIAGRAM…
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2007 > 2.7L V6 GASOLINE > PCM PROBLEM INSPECTION PROCEDURE 1. TEST PCM GROUND CIRCUIT: Measure resistance between PCM and chassis ground using the backside of PCM harness connector as PCM side check point. If the problem is found, repair it. Specification (Resistance): 1Ω…
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2007 > 2.7L V6 GASOLINE > POWERTRAIN CONTROL MODULE (PCM) 1. HARNESS CONNECTOR 2. TERMINAL FUNCTION CONNECTOR [C151-1] Description Connected to 2nd CAN [High] Multi-Purpose Check Connector 2nd CAN [Low] Multi-Purpose Check Connector Power Steering Switch signal input Power Steering Switch …
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A/C Pressure Transducer signal input A/C Pressure Transducer (APT) Sensor ground A/C Pressure Transducer (APT) Battery voltage supply after main relay Main Relay Battery voltage supply after main relay Main Relay Battery voltage supply after main relay Main Relay CAN [High] ABS/ESP Control Module…
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Variable Intake Solenoid Valve #2 control output Manifold Side] Throttle Position Sensor signal (PWM) output ABS/ESP Control Module Cruise «MAIN» lamp control output Cruise «MAIN» Lamp Fuel Pump Relay control output Fuel Pump Relay Variable Intake Solenoid (VIS) Valve #1 Surge Variable Intake Solenoid Valve #1 control output Tank Side] Immobilizer lamp control output…
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Knock Sensor (KS) [Bank 1], Knock Sensor (KS) Sensor Shield [Bank 2] Camshaft Position Sensor [Bank 2] signal input Camshaft Position Sensor (CMPS) [Bank 2] Camshaft Position Sensor [Bank 1] signal input Camshaft Position Sensor (CMPS) [Bank 1] Sensor ground HO2S [B2 / S1] [Except for LEADED] Sensor ground…
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CVVT Oil Control Valve [Bank 2] control output CVVT Oil Control Valve (OCV) [Bank 2] CVVT Oil Control Valve [Bank 1] control output CVVT Oil Control Valve (OCV) [Bank 1] Injector (Cylinder #2) control output Injector (Cylinder #2) Injector (Cylinder #3) control output Injector (Cylinder #3) …
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Hi: Battery Voltage 13.67V Alternator load signal input Idle Pulse Lo: Max 1.5 V -0.125mV Cruise Switch ground Idle Max. 50 mV 22.44mV A/C Relay OFF Battery Voltage 12.37V A/C switch «ON» signal input A/C Relay ON Max.
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IG OFF Max. 1.0 V -25mV Battery voltage supply after main relay IG ON Battery Voltage 12.37V Recessive 2.0 ~ 3.0 V 2.4V CAN [High] Pulse Dominant 2.75~4.5 V 3.56V Recessive 2.0 ~ 3.0 V 2.42V CAN [Low] Pulse Dominant 0.5~2.25 V 1.62V Relay ON…
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A/C OFF Battery Voltage 13.97V A/C Compressor Relay control output A/C ON Max. 1.0V 175mV Fan OFF Battery Voltage 13.77V Cooling Fan [Low] control output Fan ON Max. 1.0V 175mV Fan OFF Battery Voltage 13.57V Cooling Fan [High] control output Fan ON Max.
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IG ON 3.9 ~ 4.1V 3.96V Manifold Absolute Pressure Analog Sensor signal input Idle 0.8 ~ 1.6V 1.31V IG OFF Max. 0.5V 4.91V Reference voltage (+5V) IG ON 4.9 ~ 5.1V -50mV IG OFF Max.
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Power ground Idle Max. 50 mV Power ground Idle Max. 50 mV 1st Voltage: 294V Ignition Coil (Cylinder #4) control 2300~400V Idle Pulse output ON Voltage: Max. 2V 1.93V Crankshaft Position Sensor [Low] SINE Idle Vp_p: Min.1.0V 8.24V signal input WAVE …
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Battery Voltage 14.06V Injector (Cylinder #2) control Idle Pulse output Max. 1.0V 44.2mV Battery Voltage Injector (Cylinder #3) control Idle Pulse output Max. 1.0V 38.31mV Hi: Battery Voltage 14.07V Heated Oxygen Sensor [Bank 2 / Engine Run Pulse Sensor 1] Heater control output…
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Mass Air Flow Sensor (MAFS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRINCIPLE Mass Air Flow Sensor (MAFS) is a hot-film type sensor and is located in between the air cleaner and the throttle body. It consists of a tube, a sensor assembly and honeycomb cell and detects intake air quantity flowing into the intake manifold.
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COMPONENT INSPECTION 1. Check the MAFS visually. a. Mounting direction correct. b. Any contamination, corrosion or damage on connector. c. Air cleaner’s clogging or wet. d. MAFS cylinder’s deforming or blocking by any foreign material. 2. Check any leakage on intake system and intercooler system.
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Manifold Absolute Pressure Sensor (MAPS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Manifold Absolute Pressure Sensor (MAPS) is speed-density type sensor and is installed on the surge tank. This MAPS senses absolute pressure in surge tank and transfers this analog signal proportional to the pressure to the PCM.
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COMPONENT INSPECTION 1. Connect a scantool on Diagnisis Link Connector (DLC). 2. Check MAPS output voltage at idle and IG ON. Condition Output Voltage (V) Idle 0.8V ~ 1.6V IG ON 3.9V ~ 4.1V…
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Intake Air Temperature Sensor (IATS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Intake Air Temperature Sensor (IATS) is installed inside the Mass Air Flow Sensor (MAFS) and detects the intake air temperature. To calculate precise air quantity, correction of the air temperature is needed because air density varies according to the temperature.
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect IATS connector. 3. Measure resistance between IATS terminals 4 and 5. 4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Engine Coolant Temperature Sensor (ECTS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Engine Coolant Temperature Sensor (ECTS) is located in the engine coolant passage of the cylinder head for detecting the engine coolant temperature. The ECTS uses a thermistor whose resistance changes with the temperature.
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect ECTS connector. 3. Remove the ECTS. 4. After immersing the thermistor of the sensor into engine coolant, measure resistance between ECTS terminals 1 and 3. 5. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Accelerator Position Sensor (APS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Accelerator Position Sensor (APS) is installed on the accelerator pedal module and detects the rotation angle of the accelerator pedal. The APS is one of the most important sensors in engine control system, so it consists of the two sensors which adapt individual sensor power and ground line.
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COMPONENT INSPECTION 1. Connect a scantool on Diagnoisis Link Connector (DLC). 2. Start engine and check output voltages of APS 1 and 2 at C.T and W.O.T. Specification Output Voltage (V) Condition APS1 APS2 0.70 ~ 0.80 0.29 ~ 0.46 W.O.T 3.85 ~ 4.35 1.93 ~ 2.18…
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Specification: Refer to SPECIFICATION.
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Heated Oxygen Sensor (HO2S)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Heated Oxygen Sensor (HO2S) consists of zirconium and alumina and is installed on upstream and downstream of the Manifold Catalyst Converter (MCC). After it compares oxygen consistency of the atmosphere with the exhaust gas, it transfers the oxygen consistency of the exhaust gas to the PCM.
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Heater Resistance (Ω) 3.0 ~ 4.0Ω at 21°C (69.8°F) WAVEFORM CIRCUIT DIAGRAM…
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COMPONENT INSPECTION 1. Check signal waveform of HO2S using a scantool. Specification: Refer to «waveform». 2. Disconnet the HO2S connector. 3. Measure resistance between HO2S heater terminals 3 and 4.
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4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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CVVT Oil Temperature Sensor (OTS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE The CVVT Oil Temperature Sensor (OTS) is a negative coefficient thermistor used by the PCM tl measure engine oil temperature for the purpose of adjusting CVVT calculations. SPECIFICATION Temperature Resistance (kΩ) °C °F…
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect OTS connector. 3. Remove the OTS. 4. After immersing the thermistor of the sensor into water (or engine coolant), measure resistance between OTS terminals 1 and 2. 5. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Knock Sensor (KS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Knocking is a phenomenon characterized by undesirable vibration and noise and can cause engine damage. Knock Sensor (KS) senses engine knocking and the two sensors are installed inside the V-valley of the cylinder block. When knocking occurs, the vibration from the cylinder block is applied as pressure to the piezoelectric element.
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CIRCUIT DIAGRAM…
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Crankshaft Position Sensor (CKPS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Crankshaft Position Sensor (CKPS) detects the crankshaft position and is one of the most important sensors of the engine control system. If there is no CKPS signal input, fuel is not supplied and the main relay does not operate. That is, vehicle can’t run without CKPS signal.
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COMPONENT INSPECTION 1. Check signal waveform of CKPS and CMPS using a scantool. Specification : Refer to «WAVE FORM»…
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Camshaft Position Sensor (CMPS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Camshaft Position Sensor (CMPS) is a hall sensor and detects the camshaft position by using a hall element. It is related with Crankshaft Position Sensor (CKPS) and detects the piston position of each cylinder which the CKPS can’t detect.
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WAVEFORM CIRCUIT DIAGRAM…
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COMPONENT INSPECTION 1. Check signal waveform of CMPS and CKPS using a scantool. Specification : Refer to «WAVE FORM»…
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Injector…
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Based on information from various sensors, the PCM measures the fuel injection amount. The fuel injector is a solenoid-operated valve and the fuel injection amount is controlled by length of time that the fuel injector is held open. The PCM controls each injector by grounding the control circuit.
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect injector connector. 3. Measure resistance between injector terminals 1 and 2.
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4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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CVVT Oil Control Valve (OCV)
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2007 > 2.7L V6 GASOLINE > INSTALLATION If the OCVs are installed incorrectly, the vehicle may be damaged. So when installing them, ensure the OCV and harness connector colors match(Components and harness side). [Bank and its color] Bank Component side Harness side Bank 1 (RH) Grey…
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect OCV connector. 3. Measure resistance between OCV terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Variable Intake Solenoid Valve (VIS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE Variable Intake manifold Solenoid (VIS) valves are installed on surge tank (VIS Valve #1) and intake manifold (VIS Valve #2). These VIS valve #1 and #2 control vacuum modulators which activate valves in surge tank and intake manifold.
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COMPONENT INSPECTION 1. Turn ignition switch OFF. 2. Disconnect VIS Valve connector. 3. Measure resistance between VIS Valve #1,2 terminals 1 and 2. 4. Check that the resistance is within the specification. Specification: Refer to SPECIFICATION.
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Electronic Throttle System (ETS)
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2007 > 2.7L V6 GASOLINE > INSPECTION FUNCTION AND OPERATION PRICIPLE ETC (Electronic Throttle Control) system is electronically controlled throttle device which controls the throttle valve. It consists of ETC motor, throttle body and throttle position sensor (TPS). A mechanical throttle control system receives a driver’s intention via a wire cable between the accelerator and the throttle valve, while this ETC system uses the signal from the Accelerator Position Sensor (APS) installed on the accelerator pedal.
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SPECIFICATION [THROTTLE POSITION SENSOR] Output Voltage(V) [Vref = 5.0V] Throttle Angle(°) TPS1 TPS2 0° 5.0V 10° 0.5V 4.5V 20° 0.9V 4.1V 30° 1.4V 3.6V 40° 1.8V 3.2V 50° 2.3V 2.7V 60° 2.7V 2.3V 70° 3.2V 1.8V 80° 3.6V 1.4V 90° 4.1V 0.9V 100°…
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[ETC MOTOR] Item Sensor Resistance Coil Resistance (Ω) 1.275 ~ 1.725Ω at 20°C (68°F) CIRCUIT DIAGRAM FAIL-SAFE MODE Mode Description Symptom Possible Cause a. ETC system can’t proceed reliable algorithm procedure…
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algorithm procedure FORCED ENGINE MODE 1 Engine stop SHUTDOWN a. Fatal PCM internal programming error b. Faulty intake system or throttle body a. ETC system can’t control engine power FORCED IDLE & Forced idle state controlled by via throttle device MODE 2 POWER fuel quantity regulation and…
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Specification: Refer to SPECIFICATION. ETC SYSTEM INITIALIZATION 1. Erase DTC(s) memorized in PCM with a scan tool. 2. Turn ignition switch off and wait for about 10 seconds. 3. Turn ignition switch on for more then 1 second. (At this time, the PCM records initial position of ETC motor on its EEPROM).
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Fuel Delivery System…
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2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
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2007 > 2.7L V6 GASOLINE > FUEL PRESSURE TEST…
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Fuel Tank…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Preparation (1) Remove the 2nd seat(s) (Refer to «BD» group in this WORKSHOP MANUAL). (2) Remove the striker cover (A). (3) Remove the Service Cover (B). (4) Disconnect the Fuel Pump Connector (A). (5) Start the engine and wait until fuel in fuel line is exhausted.
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3. Disconnect the fuel filler hose (A) and the leveling hose (B). 4. Disconnect the fuel feed quick connector (A) and vaccum hose (B). 5. Remove the fuel tank band (A) with unscrewing the mounting bolts (B) and remove the fuel tank from the vehicle. INSTALLATION 1.
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Fuel Pump…
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2007 > 2.7L V6 GASOLINE > REMOVAL(INCLUDING FUEL FILTER AND FUEL PRESSURE REGULATOR) 1. Preparation (1) Remove the 2nd seat(s) (Refer to «BD» group in this WORKSHOP MANUAL). (2) Remove the striker cover (A). (3) Remove the Service Cover (B). (4) Disconnect the Fuel Pump Connector (A).
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INSTALLATION 1. Install the Fuel Pump assembly according to the reverse order of «REMOVAL» procedure. Fuel Pump assembly mounting bolts : 2.0 ~ 2.9 N·m (0.2 ~ 0.3 kgf·m, 1.4 ~ 2.2 lbf·ft)
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CHAPTER 6: Automatic Transaxle System…
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General Information…
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2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS TOOL Illustration (Number and name) 09200 — 38001 Removal and installation of transaxle. Engine support fixture…
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2007 > 2.7L V6 GASOLINE > SPECIFICATION Item F4A51 Torque converter type 3-element, 1-stage, 2-phase type Transaxle type 4-speed forward, 1-speed reverse Engine displacement 2.7L GSL 2.842 1.495 Gear ratio 1.000 0.731 Reverse 2.720 Final gear ratio 4.520 Shift pattern Variable Shift range 4range ( P-R-N-D) + Sports mode…
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LUBRICANT Item Specified lubricant Quantity Transmission oil Diamond ATF SP-III 8.5ℓ(9.0 Us qt, 7.5Imp.qt) SEALANT Item Specified Sealant Rear cover Torque converter housing Three Bond — TB 1281B or LOCTITE — FMD — 546 Valve body cover Transmission case side cover Three Bond — TB 1389 or LOCTITE — 518 Side cover Three Bond — TB 1389 or LOCTITE — 518/587…
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Automatic Transaxle System…
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2007 > 2.7L V6 GASOLINE > Electronic Control System DESCRIPTION The electronic control system used in the new generation auto transaxle is far superior to the previous systems. This system is able to adopt a variable shift pattern for smooth and problem free shifting. A solenoid valve is applied to each of the clutches and brakes and is independently controlled.
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OPERATING COMPONENTS AND FUNCTIONS Sensor Function Input shaft speed sensor Detect turbine speed at UD retainer Output shaft speed sensor Detect T/F drive gear speed at T/F driven gear (4A/T) Crank angle sensor Detect engine speed TPS(Gasoline) Throttle opening ratio by potentiometer Air conditioner switch A/C load by thermister Inhibitor switch…
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Sport mode up-shift switch Sport mode up-shift signal Sport mode downshift switch Sport mode downshift signal Request of torque reduction Send the request of torque reduction to ECM ABS-ECM, Engine ECM In case of CAN communication Sports Mode Sports Mode Switch Sports mode allows the manual up-shift and downshift with the accelerator pedal is depressed.
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Input signals to TCM(PCM) through ‘CAN communication’ — Engine rpm, TPS signal — A/CON signal, Engine coolant temperature — Quantity of intake airflow, Vehicle speed — Shift holding signal (FTCS ON) Output signals from TCM(PCM) through ‘CAN communication’ — Request signal for torque reduction — ATF temperature, TCM(PCM) type, TCM(PCM) error or not — Damper clutch ON, OFF / Gear position TCM PIN DESCRIPITION…
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A32 A/C Pressure Analog Recessive 2.0 ~ 3.0 V 3.85V CAN_HI Pulse Dominant 2.75 ~ 4.5 V 2.5V Recessive 2.0 ~ 3.0 V 2.55V CAN_LO Pulse Dominant 0.5 ~ 2.25 V 1.34V IG Off Max. 0.5 V IG On V_BAT IG.
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OD Solenoid Pulse Vpeak : Max. 70V 56.3V W/H Open DTC Spec : P0765 DTC : P0765 HI : V_BAT 15.4V Lock_Up on LO : Max. 1.0V 0.45V DCC solenoid Pulse Vpeak : Max. 70V 56.3V W/H Open DTC Spec : P0743 DTC : P0743 HI : V_BAT 15.4V…
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2007 > 2.7L V6 GASOLINE > Hydraulic Control System DESCRIPTION a. Better and smoother shift quality. b. In order to prevent ATF leakage from the valve body or each elements, the exhaust ports have been grouped into only one with an addition of a check ball. c.
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VFS (Variable Force Solenoid) VRS Function The spool rod in VFS is not duty cycled like one of PWM, it minutely vibrates at the range between the control port and exhaust port to control the hydraulic pressure. That is, it uses the equilibrium effect between the spring force and the magnetic force, the spring force is mechanical characteristics decided at the stage of design and the magnetic force is controlled by TCM.
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fluctuated even though turns on or off the input signal. The electrical ‘time constant’ is much more fast than one of mechanical so the frequency of VFS is extremely higher than the conventional PWM type. Characteristics of Bosch VFS: Supply pressure : 700~1600kPa Control pressure: typically 600~0 kPa Current range: typically 0~1,000 mA Dither frequency: Up to 600 Hz…
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changed by VFS so the control pressure becomes unstable and some hydraulic pressure oscillation occurred. That is why the reducing pressure has been added in the hydraulic circuit of VFS system for both 4th and 5th speed A/T. The reducing pressure is about 6.5bar and this value does not be changed regardless of the driving or engine load condition.
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↑ ↑ ↑ ↑ 1030±20(149±3) ↑ ↑ ↑ ↑ 520±40(75±6) ↑ ↑ ↑ ↑ 210±40(30±6) ↑ ↑ ↑ ↑ 1030±20(149±3) ↑ ↑ ↑ ↑ 470±40(68±6) ↑ ↑ ↑ ↑ 170±40(25±6) ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 270±40(39±6) DIR* ↑…
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D 1ST gear…
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D 2ND gear…
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D 3nd gear…
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D 4th gear…
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Reverse…
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2007 > 2.7L V6 GASOLINE > Description The automatic transmission is a combination of 3-element 2-phase 1-stage torque converter and double shaft electrocally-controlled unit which provides 4 speeds forward and 1 reverse. To improve the efficiency of power transmission, the line pressure control was changed applying “Variable Force Solenoid (VFS) valve” on this model. However, adopting VFS on this model, the line pressure is variably changed according to TPS and the vehicle speed, this will enable more improved efficiency of power transmission and fuel consumption.
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Dynamic drive by sports mode…
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MECHANICAL SYSTEM OPERATION COMPONENTS AND FUNCTION Operating Element Symbol Function Under drive clutch Connect input shaft and under drive sun gear Reverse clutch Connect input shaft and reverse sun gear Overdrive clutch Connect input shaft and over drive carrier…
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Low&Reverse brake Hold LR annulus gear and OD carrier Second brake Hold reverse sun gear One way clutch Restrict the rotating direction of low & reverse annulus gear Operating elements UD/C OD/C REV/C 2ND/B LR/B ● ● ● ● ● ●…
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Hydraulic pressure acts in the piston pressure chamber(B) (between the piston(c) and retainer) and thus pushes the piston(C). In turn, the piston depresses the clutch discs and thereby transmits driving force from the retainer(D) to the hub(E) side. At high speed, fluid remaining in the piston pressure chamber is subjected to centrifugal force and attempts to push the piston.
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BRAKES The gear changing mechanism utilizes two multi-disc brakes. LOW&REVERSE BRAKE AND SECOND BRAKE The low&reverse brake(A) operates in 1st and reverse gears, when the vehicle is parked, and during manual operation. It locks the low&reverse annulus gear and overdrive planetary carrier to the case. The second(C) brake(B) operates in 2nd and 4th gears and locks the reverse sun gear(D) to the case.
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Objective * Energy (hydraulic pressure) storage * Impact and pulsation damping when solenoid valves operating * Operation as spring element * Smooth shifting by preventing sudden operation of clutches and brakes TRANSFER DRIVE GEAR With the transfer drive gear, increased tooth height and a higher contact ratio have reduced gear noise. Also, the bearing that supports the drive gear is a preloaded type that eliminates rattle, and the rigidity of the gear mounting has been increased by bolting the bearing directly onto the case.
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MANUAL CONTROL SYSTEM MANUAL CONTROL LEVER The manual control lever is fitted to the top of the valve body and is linked to the parking roller rod and manual control valve pin. A detent mechanism is provided to improve the gear shift feeling during manual selection. PARKING MECHANISM When the manual control lever is moved to the parking position, the parking roller rod moves along the parking roller support and pushes up the parking sprag.
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1st GEAR POWER FLOW Hydraulic pressure is applied to the UD clutch(B) the LR brake(A) and the one way clutch(OWC), then the UD clutch transmits driving force from the input shaft to the UD sun gear, and the LR brake locks the LR annulus gear to the case.The UD sun gear of the planetary gear drives the output pinion gear, and the LR brake locks the annulus gear, and the output pinion drives the output carriers, and the output carrier drives the transfer drive gear, and the transfer drive gear drives the transfer driven gear of the output shaft, and power is transmitted to the differential gear through…
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3rd GEAR POWER FLOW Hydraulic pressure is applied to the UD clutch(A) and the OD clutch(B), then the UD clutch transmits driving force from the input shaft to the UD sun gear, and the OD clutch transmits driving force from the input shaft to the overdrive planetary carrier and low&reverse annulus gear.The UD sun gear of the planetary gear drives the output pinion gear and the LR annulus gear, and the LR annulus gear drives the OD pinion gear through the OD planetary carrier, and the OD pinion gear drives the reverse sun gear and the output carrier.The OD clutch drives the OD carrier, and the…
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Reverse GEAR POWER FLOW Hydraulic pressure is applied to the reverse clutch(A) and the LR brake(B), then the reverse clutch transmits driving force from the input shaft to the reverse sun gear, and the LR brake locks the LR annulus gear and OD planetary carrier to the case.The reverse clutch drives the reverse sun gear, and the reverse sun gear drives the output carrier through the OD pinion gear, and the output carrier drives the transfer drive gear, and the transfer drive gear drives the transfer driven gear of the output shaft, and power is transmitted to the differential gear through the differential drive…
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2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING DIAGNOSIS FLOW INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Probable cause Communication with HI-SCAN is not possible a. Malfunction diagnosis line If communication with the HI-SCAN is not possible, the cause is b. Malfunction of connector probably a defective diagnosis line or the TCM(PCM) is not c.
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c. Malfunction of the TCM(PCM) functioning. Driving impossible Starting impossible a. Malfunction of the engine system Starting is not possible when the selector b. Malfunction of the torque converter lever is in P or N range. In such cases, the c.
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Shocks when changing from N to D, N to R a. Abnormal line pressure and large time lag b. Malfunction of the oil pump If abnormal shocks or a time lag of 2 seconds c. Malfunction of the valve body or more occur when the selector lever is shifted from N to D range and from N to R range while the engine is idling, the cause is…
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Triple pressure switch system a. Malfunction of the triple pressure switch The cause is probably a defective dual pressure switch circuit or a b. Malfunction of connector defective TCM(PCM). c. Malfunction of A/C system d. Malfunction of the TCM(PCM) Vehicle speed sensor system a.
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3. Prohibit Adaptive Control a. No learning is done 6. Prohibit Torque Reduction Request a. No torque reduction is sent to ECU 7. Prohibit Lockup Control a. Stay in non-lockup control state 8. Substitute Input Value Oil Temperature a. Set oil temperature(tf) to 80° C (192°F) 9.
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Short to B+ DCC Solenoid valve P0743 P0743 Open or short to ground 1st speed asynchronous Synchronous error P0731 P0731 2nd speed asynchronous Synchronous error P0732 P0732 3rd speed asynchronous Synchronous error 0,11 P0733 P0733 4th speed asynchronous Synchronous error P0734 P0734 ―…
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OIL TEMPERATURE °C 40°C Current Oil temperature 80°C N,P,REV/1st G/…/5th SHIFT POSITION Current shift position P, N SELECT LEVEL P,N/R/D/SPORTS Current shift lever position P, N OFF/ON/-/NOT A/CON SWITCH SUPP OFF/ON/-/NOT IDLE STATUS When idling, ON SUPP OFF/ON/-/NOT BRAKE SWITCH When braking, ON SUPP AUTO CRUISE…
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3. P range 2ND SOLENOID(SCSV C) Solenoid valve driver for 5sec. 4. Vehicle speed 0km/h 5. Engine stop OD SOLENOID(SCSV D) 6. No failure TORQUE CONVERTER SOLENOID VALVE 7. TPS < 1V A/T CONTROL RELAY OFF for 3 sec. INTELLIGENT SHIFT PROHIBIT Prohibit until IG off CLEAR LEARNING VALUE ROAD TEST…
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(1) 100%, (2) 0%, (3) Second solenoid valve c. Driving at constant 100% speed of 30 km/h in 2nd gear (2) 100%, (3) 100%, Overdrive solenoid valve d. Driving at 50 km/h in 3rd (4) 0% gear with accelerator (1) 0km/h Vehicle speed sensor fully closed (4) 50km/h…
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5. Move the selector lever to the «D» position, fully depress the accelerator pedal and take a reading of the maximum engine speed at this time. Stall speed : 2,100~2,900rpm a. The throttle should not be left fully open for any more than five seconds. b.
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STANDARD HYDRAULIC PRESSURE TEST Measurement condition Standard hydraulic pressure kPa (psi) Damper Damper Under Selector Engine Reverse Overdrive Low&reverse Second clutch clutch Shift drive lever speed clutch clutch brake brake Apply Release position clutch position (rpm) pressure pressure pressure pressure pressure pressure pressure…
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(62-74) (62-74) 430-510 430-510 More than 0-10 3rd gear 2,500 (62-74) (62-74) 730 (100) (0-1) 430-510 780-880 More than 0-10 4th gear 2,500 (62-74) (110-130) 730 (100) (0-1) ※ The values are subject to change according to vehicle model or condition ※…
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2007 > 2.7L V6 GASOLINE > SERVICE ADJUSTMENT PROCEDURE Automatic transaxle fluid INSPECTION 1. Drive the vehicle until the fluid reaches normal operating temperature [70~80°C]. 2. Place the vehicle on a level surface. 3. Move the selector lever through all gear positions. This will fill the torque converter and the hudraulic system with fluid and move the selector lever to the «N»…
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REPLACEMENT If you have a fluid changer, use this changer to replace the fluid. If you do not, replace it using the following procedure. 1. Disconnect the hose which connects the transmission and the oil cooler which is within the radiator only in 2.4L engine(3.3L-the oil cooler is separated).
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Automatic Transaxle…
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2007 > 2.7L V6 GASOLINE > COMPONENTS (1)
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COMPONENTS (2)
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COMPONENTS (3)
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COMPONENTS (4)
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2007 > 2.7L V6 GASOLINE > REMOVAL a. Use a cover not to damage the vehicle surface. b. Disconnect connectors carefully not to be damaged. a. Mark wires or hoses for identification not to be confused. 1. Remove the battery (A). 2.
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5. Remove the inhibiter switch connector (A). 6. Remove the solenoid valve connector (A). 7. Remove the input speed sensor connector (A). 8. Remove the output speed sensor connector (A).
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9. Remove the vehicle speed sensor connector (A). 10. Remove the control cable assembly(C) by removing the nut (A) and clip (B). 11. Disconnect the transaxle oil cooler hoses (B) from the tubes by loosening the clamps (A). 12. Remove the transaxle mounting bolts (A).
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13. Remove the starter motor by disconnecting the connector. (see EE group) 14. Using the SST(09200-38001), hold the engine and transaxle assembly safely. 15. Remove the transaxle insulator mounting (B) bolts (A). 16. Remove the front wheels. (see SS group) 17.
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19. Remove the under cover (A). 20. Drain the transaxle fluid. 21. Drain power steering fluid through the return tube(A). (see ST group) 22. Disconnect the power steering pressure tube (A) from the power steering oil pump. 23. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group) 24.
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29. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly. INSTALLATION Installation is in the reverse order of removal. Perform the following : a. Adjust the shift cable. b. Refill the transaxle with fluid. c. Refill the radiator with engine coolant. d.
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8. Install the under cover (A). 9. Install the steering column joint bolt and the VRS connector (A). (see ST group) 10. Connect the return tube(A) with a clamp. (see ST group) 11. Install the front wheels and tires. 12. Tighten the transaxle insulator mounting (B) bolt (A). TORQUE: 90~110 Nm(9~11 kgf.m, 65.1~79.5 lb-ft)
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13. Tighten the transaxle mounting bolts (A). TORQUE: 65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb-ft) 14. Remove the SST (09200-38001) holding the engine and transaxle assembly. 15. Install the starter motor. (see EE group). TORQUE: 65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb-ft) 16. Connect the power steering pressure tube (A) to the power steering oil pump.
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17. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps (B). 18. Install the control cable assembly(C) by tightening the nut (A) and clip (B). TORQUE: 8~12 Nm(0.8~1.2 kgf.m, 5.8~8.6 lb-ft) 19. Install the inhibiter switch connector (A).
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20. Install the solenoid valve connector (A). 21. Install the input speed sensor connector (A). 22. Install the output speed sensor connector (A). 23. Install the vehicle speed sensor connector (A). 24. Install the battery tray (B) by removing the four mounting bolts (A).
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25. Install the air cleaner assembly (B) by tightening the two mounting bolts (A). 26. Reassemble the air cleaner filter, install the air cleaner upper body (B) and connect the air flow sensor connector (A). 27. Install the battery (A). 28.
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30. Install the engine cover. (see ‘EM’ group) When replacing the automatic transaxle, reset the automatic transaxle’s values by using the High- Scan Pro. a. Connect the Hi-Scan Pro connector to the data link connector under the crash pad and power cable to the cigar jack under the center facia.
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Valve Body System…
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Solenoid Valve…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Actuators Solenoid Valve for Pressure Control — Sensor type: Normal open 3-way — Operating temperature : -30°C~130°C(-22°F~266°F) — Frequency: LR, 2ND, UD, OD: 61.27Hz (at the ATF temp. above -20°C(-4°F)) DCC: 30.64Hz — Internal resistance: 3.0 ±…
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2007 > 2.7L V6 GASOLINE > INSPECTION 1. If the value is out of specification according to the chart below, remove the valve body cover. 2. Measure the resistance again after disconnecting solenoid valve connector. Specification (20°C): 2.5 ~ 3.5 Ω (LR, 2ND, UD, OD, TCC) 3.
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( Variable Force Solenoid) Valve…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Actuators Solenoid Valve for Pressure Control — Sensor type: Normal open 3-way — Operating temperature : -30°C~130°C(-22°F~266°F) — Frequency: LR, 2ND, UD, OD: 61.27Hz (at the ATF temp. above -20°C(-4°F)) DCC: 30.64Hz — Internal resistance: 3.0 ±…
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［46］ 2.29［224］ 1.82［178］ 1.51［148］［50］ 1.41［138］ 0.09［88］ 0.58［57］［50］ 0.65［64］ 0.14［14］ 0［0］［24］ 1,000 0.24［24］ 0［0］［24］ 1,100 0.24［24］ 0［0］ *Test condition: Ps : Supply Pressure (Ps＝7.1 ± 0.3 KGf/cm²) Pc : Control Pressure Pex : Exhaust Pressure (Atmosphere pressure) ATF : DIAMOND ATF SP-Ⅲ…
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2007 > 2.7L V6 GASOLINE > INSPECTION 1. If the value is out of specification according to the chart below, remove the valve body cover. 2. Measure the resistance again after disconnecting solenoid valve connector. Specification (20°C): 4.3 ~ 4.4Ω (VFS) 3.
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Automatic Transaxle Control System…
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Input Speed Sensor…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Input shaft speed sensor — Type: Hall sensor — Current consumption: 22mA (MAX.) — Sensor body and sensor connector have been unified as one. Hall type sensor: specification Air gap (mm) Input shaft speed sensor Coil Resistance Input shaft speed sensor over 1MΩ…
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2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Remove the battery and air cleaner (see «Transaxle range switch replacement»). 2. Remove the transaxle range switch connector. 3. Remove the control cable to transaxle range switch mounting nut. 4. Remove the input shaft speed sensor(A). (1) Disconnect the input shaft speed sensor connector.
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Output Speed Sensor…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Output shaft speed sensor — Type: Hall sensor — Current consumption: 22mA (MAX.) — Sensor body and sensor connector have been unified as one. Hall type sensor: specification Air gap (mm) Output shaft speed sensor 0.85 Coil Resistance Output shaft speed sensor…
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2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Remove the battery and air cleaner. (see «Transaxle range switch replacement») 2. Remove the output shaft speed sensor(A). (1) Disconnect the output shaft speed sensor connector(B). (2) Remove the bolt(C). (3) Inspect the output shaft speed sensor bore. 3.
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Transaxle Oil Temperature Sensor…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Oil Temperature Sensor The oil temperature sensor is of the thermistor type, and senses the automatic transaxle fluid temperature. Using the signal from this sensor, TCM(PCM) controls the shift pattern optimally during shift. In order to operate the damper clutch, this signal is also referred.
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2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Remove the automatic transaxle assembly. 2. Remove the valve body cover(refer to the overhaul manual). 3. Disconnect the oil temperature sensor connector. 4. Remove the oil temperature sensor(B), loosening the mounting bolt(A). 5.
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Inhibiter Switch…
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2007 > 2.7L V6 GASOLINE > DESCRIPTION Inhibitor Switch — Type: Rotary contact type — Range of temperature : -40°C~145°C(-40°F~293°F) Inhibitor Switch — Continuity check(Sports mode)
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2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Pull up the parking brake. 2. Position the shift lever in ‘N’ range. 3. Remove the air cleaner assembly. 4. Remove the battery. 5. Remove the battery tray. 6. Remove the inhibiter switch connector. 7.
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9. If there is not continuity between the terminals in the table above for each switch position, replace the inhibiter switch. ADJUSTMENT 1. Set the select lever to the «N» position. 2. Loosen the control cable to manual control lever coupling nut to free the cable and lever. 3.
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6. Gently pull the transmission control cable in the direction of the arrow, and then tighten the adjusting nut. 7. Check that the select lever is in the «N» position.
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CHAPTER 7: Manual Transaxle…
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General Information…
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2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Item(Namber&Name) Illustration 09452-21200 Oil seal installation Oil seal installer 09200-38001 Removal and installation of transaxle Engine supporting fixture 09455-32200 Removal of oil seal Oil seal puller 09455-21000 Removal of taper roller vearing Bearing&gear puller 09432-33200 Removal of oil seal…
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2007 > 2.7L V6 GASOLINE > SPECIFICATION Engine type µ 2.7 Manual transaxle type M5GF2 Gear ratio 3.615 1.931 1.969 1.273 0.974 Reverse 3.416 Final gear ratio 5.071 3.737 T/M oil capacity(ℓ)※ 1.9 liter (2.0077US qt, 1.6718mp qt) ※ The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must be set according to ‘INSPECTION’ or ‘REPLACEMENT’ procedure of the automatic transaxle fluid.
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Differential end play 0.15T-0.20T (0.0059T~0.0079T) Input shaft end play 0.05T-0 (0.0020T~0) 1st output shaft end play 0.05T-0.10T (0.0020T~0.0039T) 2nd output shaft end play 0.05T-0.10T (0.0020T~0.0039T) 1st gear end play 0.135T-0.435T (0.0053T~0.0171T) 2nd gear end play 0.230T-0.430T (0.0091T~0.0169T) 3rd gear end play 0.142T-0.472T (0.0056T~0.0186T) 4th gear end play 0.230T-0.430T (0.0091T~0.0169T)
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Manual Transaxle System…
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2007 > 2.7L V6 GASOLINE > SERVICE ADJUSTMENT PROCEDURE Transmission oil inspection and replacement 1. After parking the vehicle on a plain, stop the engine. 2. After removing the oil filler plug and washer, inspect the manual transaxle fluid condition and quantity. 3.
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL a. Use a cover not to damage the vehicle surface. b. Disconnect connectors carefully not to be damaged. a. Mark wires or hoses for identification not to be confused. 1. Remove the battery(A). 2.
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5. Disconnect the vehicle speed sensor connector (A) and the back up lamp switch(B). 6. Disconnect the shift cable assembly(A) after remaing the clips(B) and pins(C). 7. Remove the wire harness bracket(A).
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8. Remove C.S.C (Concentric Slave Cylinder) tube(A) which is being clamped by loosening the nut(B). 9. Remove the transaxle upper mounting bolts(A). 10. Support the engine and transaxle by using the special tool (09200-38001).
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11. Remove the transaxle insulator bracket (B) by removing the bolts (A). 12. Remove the front wheels and tires. (see SS group) 13. Lift up the vehicle. 14. Remove the steering column joint bolt. (see ST group). 15. Remove the under cover(A). 16.
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17. Disconnect the power steering pressure hose (A) from the power steering oil pump. (see ST group) 18. Drain the tranaxle fluid through the drain plug. 19. Remove the hanger(A). 20. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group) 21.
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23. Remove the rear roll stopper mounting bolts(A). 24. Disconnect the VRS connector(A). (see ST group) 25. Remove the mounting bolts from the sub frame by supporting the sub frame(A) with a jack. (see SS group) 26. Remove the exhaust pipe(A).
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27. Remove the inner shaft bracket mounting bolt(A). RH 28. Remove the drive shafts(A) from the transaxle. (see DS group) 29. Remove the side cover(A).
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30. Remove the starter motor cover(A). 31. Disconnect the starter motor connector and remove the starter motor(A). (see EE group) 32. Remove the mounting bolts(A) of lower part of the transaxle, and remove the transaxle assembly by supporting it with a jack. INSTALLATION 1.
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2. Tighten the transaxle under mounting bolts. TORQUE: 65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb-ft) 3. Install the starter motor(A) and connect the starter motor connector. (see EE group) TORQUE: 65~85 Nm(6.5~8.5 kgf.m, 47.0~61.5 lb-ft) 4. install the starter motor cover(A). 5. install the side cover(A).
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6. Install the drive shafts(A) to the transaxle. (see DS group) 7. Install the inner shaft bracket mounting bolt(A). (see DS group) 8. Install the exhaust pipe(A). TORQUE: 39.2~58.8Nm(4.0~6.0kgf.m, 28.9~43.4lb-ft)
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9. Install the sub frame(A). (see SS group) TORQUE: 60~80Nm(6.0~8.0kgf.m, 65.1~79.5lb-ft) 10. Connect the vrs connector(A). (see ST group) 11. Install the rear roll stopper mounting bolts(A).
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12. Install the power steering return tube mounting bolt(A). 13. Install the front roll stopper mounting bolt(A). 14. Connect the lower arm, the rod end ball joint, the stabilizer bar link to the front knuckle.(see SS group) 15. Install the hanger(A). 16.
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19. Install the under cover(A). 20. Install the steering column joint bolt.(See ST group). 21. Install the front wheels and tires. (see SS group) 22. Install the transaxle insulator and mounting bracket (B) by tightening the bolts (A). TORQUE: 60~80 Nm (6~8 kgf.m, 43.6~58.2 lb-ft) 23.
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24. Install the transaxle upper mounting bolts(A). TORQUE: 65~85Nm(6.5~8.5kgf.m, 47.0~61.5lb-ft) 25. Install the C.S.C (Cincentric Slave Cylinder) tube(A) by tightening the nut(B).
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26. Install the wire harness bracket(b). 27. Install the shift cable assembly (A) with the clips(B) and pins(C). 28. Install the vehicle speed sensor connector (A) and the back up lamp switch(B). 29. Install the battery tray(B) by removing the four mounting bolts(A).
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30. Install the air cleaner assembly(B) by tightening the two mounting bolts(A). 31. Reassemble the air cleaner filter, install the air cleaner upper body(B) and connect the air flow sensor connector(A). 32. Install the battery(A).
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CHAPTER 8: Driveshaft and Axle…
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General Information…
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2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Tool(Number and name) Illustration Tie rod end puller Separation of a lower arm and a tie 09568-4A000 rod end ball joint Front hub remover and installer Removal of a front hub from a 09517-21500 knuckle.
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2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Symptom Possible cause Remedy Vehicle pulls to one side Scoring of driveshaft ball joint Replace Wear, rattle or scoring of wheel bearing Replace Defective front suspension and steering Adjust or replace Vibration Wear, damage or bending of driveshaft Replace Driveshaft rattle and worn hub splines Replace…
Page 446
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS Driveshaft Joint type Max. permissible angle Engine Transaxle Inner Outer Inner Outer TSJ#26 BJ#28 46.5° 23° 2.9 CRDi UTJ-II#25 BJ#26 46.5° 23° 3.8 MPI UTJ-II#25 BJ#26 46.5° 23° Front hub & bearing assembly Starting torque 1.97 Nm (20 kgf.cm, 1.45 lb-ft) Rear hub &…
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BJ#28 250 g BJ#26 210 g TSJ#26 150 g UTJ-II#25 CK-2 220 g…
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Driveshaft Assembly Front Driveshaft…
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2007 > 2.7L V6 GASOLINE > COMPONENTS COMPONENTS…
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COMPONENTS…
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2007 > 2.7L V6 GASOLINE > REMOVAL 1. Raise the vehicle and remove the wheel & tire assembly (A) from the front hub assembly (B). Tightening torque Nm (Kgf.m, lb-ft): 90 ~ 110 (9.0 ~ 11.0, 65 ~ 80) 2. Unstake the driveshaft lock nut using a chisel and hammer. 3.
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4. Remove the split pin and castle nut form the tie rod end ball joint. Tightening torque Nm (Kgf.m, lb-ft): 60 ~ 80 (6.0 ~ 8.0, 43 ~ 58) 5. Disconnect the tie rod end (A) from the knuckle using a SST (09568-4A000). 6.
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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)
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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.
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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.
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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.
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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.
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7. Remove both side of bands(B) of the dunamic damper(A). 8. Fix the drive shaft(A) with a vice(B) as illustrated. 9. Apply soapy water to the shaft to prevent being damaged between the shaftspline and the dynamic damper when the dynamic damper is removed. 10.
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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.
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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).
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9. Remove both side of bands (B, C) of the dynamic damper (A). 10. Fix the driveshaft (A) with a vice (B) as illustrated. 11. Apply soap powder on the shaft to prevent being damage between the shaft spline and the dynamic damper when the dynamic damper is removal.
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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.
Page 464
(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] Standard (A) mm(in) Items…
Page 466
Front Axle Assembly…
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Front Hub — Axle…
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2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 469
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Raise the vehicle and remove the wheel & tire assembly (A) from the front hub assembly (B). Tightening torque Nm (Kgf.m, lb-ft): 90 ~ 110 (9.0 ~ 11.0, 65 ~ 80) 2. Remove the wheel speed sensor & wire (A) by loosening the bolts. 3.
Page 470
5. Remove the driveshaft lock nut (A). Tightening torque Nm (kgf,m, lb-ft): 245 ~ 275 (24.5 ~ 27.5, 177 ~ 199) 6. Remove the caliper assembly (A) from the knuckle and suspend it with wire. Tightening torque Nm (kgf,m, lb-ft): 85 ~ 100 (8.5 ~ 10.0, 61 ~ 72)
Page 471
7. Remove the split pin and castle nut from the tie rod end ball joint. Tightening torque Nm (Kgf.m, lb-ft): 60 ~ 80 (6.0 ~ 8.0, 43 ~ 58) 8. Disconnect the tie rod end (A) from the knuckle using a SST (09568-4A000). 9.
Page 472
Tightening torque Nm (Kgf.m, lb-ft): 90 ~ 120 (9.0 ~ 12.0, 65 ~ 87) 10. Using a plastic hammer, disconnect the driveshaft (A) from the front hub assembly (B). 11. Remove the brake disc (A) from the front hub assembly. 12.
Page 473
Tightening torque Nm (kgf.m, lb-ft): 100 ~ 120 (10.0 ~12.0, 72 ~ 87) INSTALLATION 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.
Page 474
INSPECTION 1. Check the hub for cracks and the splines for wear. 2. Check the brake disc for scoring and damage. 3. Check the knuckle for cracks. REASSEMBLY 1. Reassembly is reverse of the disassembly. 2. Measure the wheel bearing starting toque. 20 kgf.cm or less 3.
Page 475
Rear Axle Assembly…
Page 476
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 477
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Release the parking brake. 2. Remove the wheel & tire assembly. Tightening torque Nm (kgf.m, lb-ft): 90 ~ 110 (9.0 ~ 11.0, 65 ~ 80) 3. Support lower part of the lower arm (A) using a jack and remove the bolt & nut (B). Tightening torque Nm (kgf.m, lb-ft): 160 ~ 180 (16.0 ~ 18.0, 116 ~ 130) 4.
Page 478
6. Remove the rear brake caliper assembly (A) from the carrier assembly and suspend it with wire. Tightening torque Nm (kgf.m, lb-ft): 50 ~ 60 (5.0 ~ 6.0, 36 ~ 43) 7. Remove the rear brake disc (A) by loosening the screws. 8.
Page 479
9. Remove the lock nut (A) and washer (B). Tightening torque Nm (kgf.m, lb-ft): 200 ~ 260 (20.0 ~ 26.0, 145 ~ 188) 10. Remove the hub & bearing assembly (A). 11. Disconnect the parking brake cable (A) from the brake assembly.
Page 480
12. Remove the clip (A) and bracket mounting bolt and disconnect the parking brake cable (B) from the carrier assembly. 13. Remove the rear brake assembly (A). Tightening torque Nm (kgf.m, lb-ft): 50 ~ 60 (5.0 ~ 6.0, 36 ~ 43) 14.
Page 481
16. After loosening the castle nut and split pin, disconnect the upper arm (A) from the carrier assembly using a SST (09562-4A000). Tightening torque Nm (kgf.m, lb-ft): 90 ~ 100 (9.0 ~ 10.0, 65 ~ 72) 17. Remove the carrier assembly (A) from the trailing arm by loosening the bolts. Tightening torque Nm (kgf.m, lb-ft): 80 ~ 110 (8.0 ~ 11.0, 58 ~ 80) INSTALLATION…
Page 482
2. Check the rear hub & bearing assembly starting torque using a spring balance. 20 kgf.cm INSPECTION 1. Check the hub for cracks and wear. 2. Check the brake disc for scoring and damage. 3. Check the carrier for cracks.
Page 483
CHAPTER 9: Suspension System…
Page 484
General Information…
Page 485
2007 > 2.7L V6 GASOLINE > SPECIAL SERVICE TOOLS Tool (Number and Name) Illustration 09568-4A000 Removal of Ball joint Ball joint remover (Front upper arm/lower arm, & Rear upper arm) 09532-11600 Measurement of the front lower arm Preload socket ball joint starting torque. (Use with torque wrench) 09546-26000 Compression of the coil spring…
Page 486
09552-38100 Removal and installation of the rear Rear trailing arm bushing remover trailing arm bushing and installer (Use with 09216-21600)
Page 487
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Vehicle inspection SYMPTOM CHART Symptom Suspect Area Remedy (See page) Squeak or grunt-noise from the front Front stabilizer bar Under these conditions, the noise is suspension, occurs more in cold acceptable. ambient temperatures-more noticeable over rough roads or when turning Clunk-noise from the front…
Page 488
accelerating around a corner See DS group — driveshaft. Front suspension noise — A squeak, Steering components Go to detailed test A. creak, or rattle noise — occurs mostly Loose or bent front struts or shock over bumps or rough roads absorbers Damaged spring or spring mounts Damaged or worn arm bushings…
Page 489
Loosen wheel nuts Check the wheel nuts. Tighten to specification. Damaged or uneven tire wear Spin the tire and Check for abnormal tire wear or damage. Install a new tire as necessary. Tire shimmy or shake — occurs at Wheel/tire out of balance lower speeds Uneven tire wear Check for abnormal tire wear.
Page 490
Strut and spring assembly Spring and strut mounting Front lower arm ball joint Front lower arm mounting bolt bushing Stabilizer bar bushings Wheel hubs and bearing Rear suspension arms and bushings Tire/wheel Inflate tires to specification. Vehicle load Redistribute the load as necessary. Vehicle leans Suspension components Visually inspect the suspention…
Page 491
● Are the front springs or spring mounts/brackets worn or damaged ? → YES Repair or Install new components as necessary. Test the system for normal operation. → NO Go toA5. CHECK THE STABILIZER BAR a. Check the stabilizer bar bushings and links for damage or wear. b.
Page 492
operation. → NO Go toB4. CHECK THE TRAILING ARMS a. Inspect the trailing arm bushings for wear or damage. Check for loose trailing arm bolts. b. Inspect for twisted or bent trailing arms. ● Are the trailing arms loose, damaged or worn ? →…
Page 493
c. Inspect the tire wear pattern. ● Do the tires have an abnormal wear pattern ? → YES Correct the condition that caused the abnormal wear. Install new tire(s). Test the system for normal operation. → NO Go to TIRE ROTATION DIAGNOSIS a.
Page 494
specification for total lateral runout is 2.5mm (0.098 inch). ● Is the lateral runout within specifications ? → YES Wheel and tires are OK. Conduct diagnosis on other suspect systems. → NO Go toC9. LATERAL RUNOUT CHECK ON THE WHEEL Measure the lateral runout of the wheel.
Page 495
Go toD3. → NO Adjust or Repair as necessary. Test the system for normal operation. MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON THE VEHICLE Measure the lateral runout and the radial runout of the front wheels on the vehicle.
Page 496
Dismount the tire and mount the wheel on a wheel balancer. Measure the runout on both wheel flanges. Go to detailed test C ● Is the runout within specifications ? → YES Locate and Mark the low spot on the wheel. Install the tire, matching the high spot on the tire with the low spot on the wheel.
Page 497
Check the vehicle alignmnt. ● Is the alignment within specification ? → YES Go to → NO Adjust the alignment as necessary. See page SS-69 (wheel alignment). BRAKE DRAG DIAGNOSIS Apply the brakes while driving. ● Does drift or pull occur when the brakes are applied ? →…
Page 498
→NO Replace bent or damaged parts. CHECK THE REAR SUSPENSION a. Measure the vehicle wheel base for LH and RH. b. Compare the measurements. ● Are the measurements the same ? → YES If the ride is smooth, vehicle is OK. If the ride is rough, Go to Detailed Test →…
Page 499
Install new spring and/or stabilizer bars. → NO Go toI3. INSPECT THE FRONT SUSPENSION Inspect the front suspension components for excessive wear or damage. ● Are the front suspension components worn or damaged ? → YES Install new front suspension components. →…
Page 500
● Is the vibration present ? → YES Go toK2. → NO The vehicle is OK. Go toTROUBLESHOOTING. INSPECT THE TIRES a. Raise and support the vehicle with a frame contact hoist. b. Inspect the tires for extreme wear or damage, cupping, or flat spots. ●…
Page 501
a. Substitute a known good set of wheels and tires. b. Perform a road test. c. If the vehicle still exhibits a shake or vibration, note the vehicle speed and/or engine rpm which it occurs. ● Is the vibration felt ? →…
Page 502
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS FRONT SUSPENSION SYSTEM Items Specification Type Macpherson strut Type Stroke mm (in) 195.5 (7.70) Expansion mm (in) 595.5 ± 3 (23.44 ± 0.12) 400 + 3, -Free (15.75 + 3, Compression mm (in) Free) DIESEL WHITE…
Page 503
610.0~642.2 Yellow 1 point Spring Free height mm (in) 291.1(11.46) White 2 point GASOLINE 623.6~653.0 Load(kg) I.D. Color 594.2~623.6 White 1 point WHEELS AND TIRES Items Specification 225/70 R16 Tire Size 235/60 R17 Steel 6.5J×16 Wheel Size 6.5J×16 Aluminium 6.5J×17 …
Page 504
Rear shock absorber bracket mounting bolt(to body) 80 ~ 110 8 ~ 11 57.9 ~ 79.5 Rear shock absorber bracket mounting nut(to body) 90 ~ 120 9~ 12 65.1 ~ 86.8 Rear shock absorber nut (to rear knuckle) 140 ~ 160 14 ~ 16 101.2 ~ 115.7 Rear upper arm ball joint nut (to rear knuckle)
Page 505
Front Suspension System…
Page 506
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 507
Front Strut Assembly…
Page 508
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 509
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. 2. Remove the front wheel and tire (A) from front hub (B). Be careful not to damage to the hub bolts (C) when removing the front wheel and tire (A). 3.
Page 510
6. Remove the strut upper mounting nuts(A). 7. Remove the front strut assembly (A) bolts (B) from the front knuckle. INSTALLATION 1. Install the strut upper mounting nuts (A). Tightening torque Nm (kgf.m, lb-ft) : 45 ~ 60 (4.5 ~ 6.0, 32.5 ~ 43.4)
Page 511
2. Install the front strut assembly (A) bolts (B) to the front knuckle. Tightening torque Nm (kgf.m, lb-ft) : 100 ~ 120 (10 ~ 12, 72.3 ~ 86.8) 3. Install the front stabilizer link (A) nut (B) to the strut assembly. Tightening torque Nm (kgf.m, lb-ft) : 100 ~ 120 (10 ~ 12, 72.3 ~ 86.8) 4.
Page 512
5. Install the brake hose bracket bolt (A, B) to the axle assembly. Tightening torque Nm (kgf.m, lb-ft) : 6.9 ~ 11 (0.7 ~ 1.1, 5.1 ~ 8.0) 6. Install the wheel and the tire (A) to the front hub (B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) Be careful not to damage the hub bolts(C) when installing the front wheel and tire(A).
Page 513
2. Remove the self-locking nut (C) from the strut assembly (B). 3. Remove the insulator, spring seat, coil spring and dust cover from the strut assembly. INSPECTION 1. Check the strut insulator for wear or damage. 2. Check rubber parts for damage or deterioration. 3.
Page 514
b. Install the coil spring wth the identification mark directed toward the knuckle. 3. After fully extending the piston rod, install the spring upper seat and insulator assembly. 4. After seating the upper and lower ends of the coil spring (A) in the upper and lower spring seat grooves (B) correctly, tighten new self-locking nut temporarily.
Page 515
Front Lower Arm…
Page 516
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 517
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. 2. Remove the front wheel and tire (A) from front hub (B). Be careful not to damage the hub bolts(C) when removing the front wheel and tire(A). 3.
Page 518
2. Apply soap solution to the following parts. a. Outer surface of the bushing. b. Inner surface of the lower bushing mounting part. 3. Using the special tools(09214-32000 & 09216-21100), install the busing on the lower arm. Insert bushing in the direction shown in the illustration. Separation force is over 100 Nm (1000Kgf, 2204 lbf) INSTALLATION 1.
Page 519
2. Install the front lower arm (A) ball joint mounting bolt (B) to the knuckle. Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 120 (9 ~ 12, 65.1 ~ 86.8) 3. Install the wheel and the tire(A) to the front hub(B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) Be careful not to damage the hub bolts(C) when installing the front wheel and tire(A).
Page 520
4. Check all bolts. 5. Check the lower arm ball joint for rotating torque. (1) If a crack is noted in the dust cover, replace the ball joint assembly. (2) Move the ball joint stud several times in a circular motion. (3) Measure the ball joint rotating torque.
Page 521
Front Stabilizer Bar…
Page 522
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 523
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the connecting bolt (A) between the steering universal joint assembly (B) and the pinion assembly. 2. Loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. 3.
Page 524
6. Remove both sides of the lower arm (A) mounting bolts (B). 7. Remove the engine mounting bolts (A, B)
Page 525
8. Remove the twelve bolts and nuts of the sub frame by supporting it with a jack. 9. After lowering the jack which supports the sub frame in a proper level, remove both sides of the stabilizer bar assembly mounting bolts (A). 10.
Page 526
INSTALLATION 1. Install the bushing (B) on the stabilizer bar (A). Bring clamp (C) of stabilizer bar (A) into contact with bushing (B). 2. Install the bracket on the bushing (B). 3. After tightening the bolts of the bushing bracket temporarily, install the bushing bracket on the opposite side. 4.
Page 527
6. Install the engine mounting bolts (A, B) Tightening torque Nm (kgf.m, lb-ft) : 65 ~ 85 (6.5 ~ 8.5, 47.0 ~ 61.5) 7. Install both sides of the lower arm (A) mounting bolts(B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 120 (9 ~ 12, 65.1 ~ 86.8) 8.
Page 528
specification. Tightening torque Nm (kgf.m, lb-ft) : 65 ~ 80 (6 ~ 8, 43.4 ~ 57.8) 9. Install the front stabilizer link (A) nut (B) to the strut assembly. Tightening torque Nm (kgf.m, lb-ft) : 100 ~ 120 (10 ~ 12, 72.3 ~ 86.8) 10.
Page 529
Tightening torque Nm (kgf.m, lb-ft) : 13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0) After installation, if neccessary, adjust the alignment of the steering wheel and front tires INSPECTION 1. Check the bushing for wear and deterioration. 2. Check the stabilizer bar for bending or breakage. 3.
Page 530
Rear Suspension System…
Page 531
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 532
Rear Shock Absorber…
Page 533
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 534
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 535
INSTALLATION 1. Install the connecting bolt (A) between the rear shock absorber and the bracket. Tightening torque Nm(kgf.m, lb-ft) : 160 ~ 180 (16 ~ 18, 115.7 ~ 130.2) 2. Install the rear shock absorber (A) to the knuckle temporarily. 3.
Page 536
4. Install the rear shock absorber (A) nut (B) to the knuckle. Tightening torque Nm(kgf.m, lb-ft) : 160 ~ 180 (16 ~ 18, 115.7 ~ 130.2) 5. Install the wheel and the tire (A) to the rear hub (B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A).
Page 537
Rear Upper Arm…
Page 538
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 539
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 540
5. Remove the rear upper arm ball joint (A) by using the special tool(09568-4A000). 6. Remove the rear upper arm (A) mounting nut (B) from the cross member. INSTALLATION 1. Install the rear upper arm (A) mounting nut (B) to the cross member. Tightening torque Nm (kgf.m, lb-ft) : 160 ~ 180 (16 ~ 18, 115.7 ~ 130.2)
Page 541
2. Install the rear upper arm ball joint self-locking nut (A) and the cotter pin. Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) 3. Install the brake caliper mounting bolts (A). Tightening torque Nm (kgf.m, lb-ft) : 50 ~ 60 (5.0 ~ 6.0, 36.2 ~ 43.4) 4.
Page 542
Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A). INSPECTION 1. Check the bushing for wear and deterioration. 2. Check the upper arm for bending or breakage. 3. Check the ball joint for rotating torque. (1) If there is a crack in the dust cover, replace it and add grease.
Page 543
Rear Lower Arm…
Page 544
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 545
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 546
INSTALLATION 1. Pretighten the lower arm (A) mounting bolts (B) to the cross member. 2. Install the spring (A), the lower seat, and the upper pad. 3. Install the lower arm bolt (B) to the rear knuckle and the lower arm bolt (C) to the cross member with a specified torque, while supporting the lower arm (A) with a jack as shown in the illustration.
Page 547
4. Install the wheel and the tire (A) to the rear hub (B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A). INSPECTION Rear lower arm 1.
Page 548
Rear Assist Arm…
Page 549
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 550
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 551
5. Remove the rear assist arm ball joint (A) by using the special tool(09568-4A000). 6. Remove the rear assist arm (A) mounting nut (B) from the cross member. INSTALLATION 1. Install the rear assist arm (A) mounting nut (B) to the cross member. Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 120 (9 ~ 12, 65.1 ~ 86.8)
Page 552
2. Install the rear assist arm (A) ball joint self-locking nut (B) and the cotter pin. Tightening torque Nm (kgf.m, lb-ft) : 160 ~ 180 (16 ~ 18, 115.7 ~ 130.2) 3. Install the brake caliper mounting bolts (A). Tightening torque Nm (kgf.m, lb-ft) : 50 ~ 60 (5.0 ~ 6.0, 36.2 ~ 43.4) 4.
Page 553
Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A). INSPECTION 1. Check the bushing for wear and deterioration. 2. Check the upper arm for bending or breakage. 3. Check the ball joint for rotating torque. (1) If there is a crack in the dust cover, replace it and add grease.
Page 554
Trailing Arm…
Page 555
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 556
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 557
6. Remove the stabilizer link (B) nut (C) from the trailing arm (A). 7. Remove the trailing arm bracket (A) mounting bolts (B) from the body. 8. Remove the connecting bolt (B) between the trailing arm (A) and the bracket. INSTALLATION 1.
Page 558
2. Install the trailing arm bracket (A) mounting bolts (B) from the body. Tightening torque Nm (kgf.m, lb-ft) : 80 ~ 110 (8 ~ 11, 57.9 ~ 79.5) 3. Install the trailing arm (A) mounting nuts (B) from the knuckle. Tightening torque Nm (kgf.m, lb-ft) : 80 ~ 100 (8 ~ 10, 57.9 ~ 72.3) 4.
Page 559
5. Remove the wheel speed sensor wire’s bracket bolt (A) and the parking brake wire’s bracket bolt (B). Tightening torque Nm (kgf.m, lb-ft) : 7 ~ 11 (0.7 ~ 1.1, 5.1 ~ 8.0) 6. Install the wheel speed sensor wire’s bracket bolt (A) from the body and the connector. Tightening torque Nm (kgf.m, lb-ft) : 7 ~ 11 (0.7 ~ 1.1, 5.1 ~ 8.0) 7.
Page 560
Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A). INSPECTION 1. Check the bushing for wear and deterioration. 2. Check the trailing arm for bending or breakage. 3. Check all the bolts for damage.
Page 561
Rear Stabilizer Bar…
Page 562
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 563
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Loosen the wheel nuts slightly. Raise the rear of the vehicle, and make sure it is securely supported. 2. Remove the rear wheel and tire (A) from rear hub (B). Be careful not to damage the hub bolts (C) when removing the rear wheel and tire (A). 3.
Page 564
INSTALLATION 1. Install the rear stabilizer link (A) nut (B) to the stabilizer bar assembly. Tightening torque Nm (kgf.m, lb-ft) : 50 ~ 65 (5.0 ~ 6.5, 36.2 ~ 47.0) 2. Install the bushing (B) on the stabilizer bar (A). Bring clamp (C) of stabilizer bar (A) into contact with bushing (B).
Page 565
5. Install the stabilizer link (B) nut (C) to the trailing arm (A). Tightening torque Nm (kgf.m, lb-ft) : 50 ~ 65 (5.0 ~ 6.5, 36.2 ~ 47.0) 6. Repeat step 4 and 5 for the other side. 7. Install the wheel and the tire (A) to the rear hub (B). Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~ 11, 65.1 ~ 79.5) Be careful not to damage the hub bolts (C) when installing the rear wheel and tire (A).
Page 566
3. Check the ball joint for rotating torque. (1) If there is a crack in the dust cover, replace it and add grease. (2) Shake the stabilizer link ball joint stud several times. (3) Mount the self-locking nut on the ball joint, and then measure the ball joint rotating torque. Specified torque : 0.5 ~ 2.5 Nm (5 ~ 25 kgf.m, 3.62 ~ 1.81 lb-ft) Measure torque using the special tool(09532-11600) and torque wrench at the range of 0.5 — 2 rpm after…
Page 567
Tires / Wheels…
Page 568
Tires…
Page 569
2007 > 2.7L V6 GASOLINE > TIRE WEAR 1. Measure the tread depth of the tires. Tread depth [limit] : 1.6 mm (0.063 in) 2. If the remaining tread(A) depth is less than the limit, replace the tire. When the tread depth of the tires is less than 1.6 mm (0.063 in), the wear indicators(B) will appear. TIRE ROTATION Rotate the tires in the pattern illustrated.
Page 570
2. If the steering pulls to the opposite side, rotate the front and rear tires, and perform a road test again. 3. If the steering continues to pull to one side, rotate the front right and left tires again, and perform a road test. 4.
Page 571
Wheel…
Page 572
2007 > 2.7L V6 GASOLINE > WHEEL ALIGNMENT When using commercially available computerized four wheel alignment equipment (caster, camber, toe) to inspect the front wheel alignment, always position the car on a level surface with the front wheels facing straight ahead. Prior to inspection, make sure that the front suspension and steering system are in normal operating condition and that the wheels and tires face straight ahead and the tires are inflated to the specified pressure.
Page 573
[REAR] Standard value : Toe-in (B-A) mm (in) : 2.6 ± 2 (0.1024 ± 0.0787) Adjust the toe-in by turning the cambolt of the assist arm. Left cambolt : Clockwise → toe-in Right cambolt : Clockwise → toe-out The variation of toe by a rotation of the cambolt : About 3.2 mm (0.126 in) a.
Page 574
Item Description Positive camber angle True vertical When the wheel tilts out at the top, then the camber is positive (+). When the wheel tilts in at the top, then the camber is negative(-). Standard value : 0° ± 30´ Difference between right and left angle is within 0°…
Page 575
the bent or damaged parts. Caster : 3°46´ ± 30´ (to ground), 4°40´ (to body) a. The worn loose or damaged parts of the front suspension assembly must be replaced prior to measuring front wheel alignment. b. Caster are pre-set to the specified value at the factory and don’t need to be adjusted. c.
Page 576
WHEEL NUT TIGHTENING 1. Tightening torque. Tightening torque Nm (kgf.m, lb-ft) : 90 ~ 110 (9 ~11, 65.1 ~ 79.5) When using an impact gun, final tightening torque should be checked using a torque wrench. 2. Tightening order. Check the torque again after tightening the wheel nuts diagonally.
Page 577
CHAPTER 10: Steering System…
Page 578
General Information…
Page 579
2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Tool (Number and Name) Illustration 09222-32100 Installation of the oil pump oil seal Valve stem oil seal installer 09555-21000 Removal and installation of the oil seal (Use with 09573-33100, 09573- 33000,09573-21000) 09561-11001 Removal of steering wheel Steering wheel puller 09568-4A000…
Page 580
09572-22100 Measurement of the oil pressure Oil pressure gauge adapter (Use with 09572-21000, 09572- 21200) 09573-21100 Installation of the back up washer Oil seal installer and oil seal (Use with 09753-21000,09573- 33100, 09555-21000) 09573-33100 Removal and installation of the oil Oil seal guide seal (Use with 09573-21000, 09573-…
Page 581
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Symptom Probable cause Remedy Excessive play in Loose yoke plug Retighten steering Loose steering gear mounting bolts Retighten Loose or worn tie rod end Retighten or replace as necessary Steering wheel V-belt slippage Readjust operation is not Damaged V-belt…
Page 582
2007 > 2.7L V6 GASOLINE > SERVICE ADJUSTMENT PROCEDURE CHECKING STEERING WHEEL FREE PLAY 1. Start the engine and with the steering wheel in the straight ahead position. 2. Measure the play while turning the steering wheel to the left and right. Standard value : Steering wheel free play : 30 mm (1.1 in) 3.
Page 583
2. Shake the ball joint stud several times to check for looseness. Tie rod end ball joint starting torque : 30 kg·cm or less 3. If the starting torque exceeds the upper limit of the standard value, replace the tie rod end. 4.
Page 584
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).
Page 585
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.
Page 586
5. Remove the special tools, and tighten the pressure hose to the specified torque. Tightening Torque Nm(kgf·m, lb-ft) : 65 ~ 75(6.5 ~ 7.5, 47 ~ 54) 6. Bleed the system.
Page 587
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS Items Specifications Type Tilt Steering column/ shaft Tilt stroke +7°/ -11.7° Type Rack & pinion Steering gear VRS On 148 mm (5.827 in) Rack stroke VRS Off 156 mm (6.142 in) Type Vane Relief pressure 90 kgf/cm²…
Page 588
Steering Column & Shaft…
Page 589
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 590
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.
Page 591
Tightening torque Nm (kgf.m, lb-ft): 40 ~ 50 (4.0 ~ 5.0, 29 ~ 36) 4. After making the marks on the steering wheel and shaft for reinstallation, remove the steering wheel using a SST (09561-11002). Do not hammer on the steering wheel to remove it ; it may damage the steering column. 5.
Page 592
8. Disconnect the connectors (A) and remove the mutifunction switch (B). 9. Loosen the bolt (A) and then disconnect the universal joint assembly (B) from the steering gear assembly. Tightening torque Nm (kgf.m, lb-ft): 13 ~ 18 (1.3 ~ 1.8, 9.4 ~ 13.0) 10.
Page 593
INSTALLATION Before installing, apply multi purpose grease to each moving parts. 1. Installation is the reverse of removal. Align the marks on the steering wheel and shaft for reinstallation when installing the steering wheel. DISASSEMBLY KEY LOCK ASSEMBLY 1. Make a groove on head of the special bolt (A) by using a punch. 2.
Page 594
4. Tighten the special bolt until its head is cut off. UNIVERSAL JOINT ASSEMBLY 1. Remove the universal joint (B) assembly from the steering column assembly (C) by loosening the bolt (A). 2. Reassembly is the reverse of disassembly. INSPECTION 1.
Page 595
Hydraulic Power Steering System…
Page 596
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 597
Power Steering Gear…
Page 598
2007 > 2.7L V6 GASOLINE > COMPONENT…
Page 599
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.
Page 600
[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)
Page 601
7. Remove the split pin and lower arm bolts and nut (A). Tightening torque Nm (kgf-m, lb-ft): 90 ~ 120 (9.0 ~ 12.0, 65 ~ 87) 8. Disconnect the stabilizer link (B) from the strut assembly (A) by loosening nut. Tightening torque Nm (kgf.m, lb-ft): 100 ~ 120 (10.0 ~ 12.0, 72 ~ 87) 9.
Page 602
11. Remove the sub-frame by loosening the bolts and nuts. 12. Remove the rear roll stopper (A) from the sub-frame. 13. Disconnect the pressure tube (A) and return (B) from the valve body housing. Tightening torque Nm (kgf.m, lb-ft): 12 ~ 18 (1.2 ~ 1.8, 9 ~ 13)
Page 603
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.
Page 604
2. Remove the dust cover (B) from the ball joint (A). 3. Remove the bellows band (A). 4. Remove the bellows clip (A). 5. Pull the bellows out toward the tie rod.
Page 605
Check for rust on the rack when the bellows are replaced. 6. Remove the feed tube(A) from the rack housing. 7. While moving the rack slowly, drain the fluid from the rack housing. 8. Unstake the tab washer (A) which fixes the tie rod (B) and rack (C) with a chisel. 9.
Page 606
11. Remove the yoke plug (B) with a 14mm socket (A). 12. Remove the lock nut (D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box. 13. When the end of the circlip comes out of the notchedhole of the housing rack cylinder, turn the rack stopper (A) clockwise and remove the circlip.
Page 607
14. When the end of the circlip comes out of the notched hole (A) of the housing rack cylinder, turn the rack stopper (B) counterclockwise and remove the circlip. Be careful not to damage the rack. 15. Remove the rack bushing and rack from the rack housing. 16.
Page 608
18. Remove the valve body (A) from the valve body housing (B) with a soft hammer. 19. Using the special tool, remove the oil seal and ballbearing from the valve body housing. 20. Remove the oil seal and O-ring from the rack housing. Be careful not to damage the pinion valve cylinderinside of the rack housing.
Page 609
(4) Check for oil seal ring damage or wear. (5) Check for oil seal damage or wear. 2. Pinion valve (1) Check for pinion gear tooth face damage or wear. (2) Check for oil seal contact surface damage. (3) Check for seal ring damage or wear. (4) Check for oil seal damage or wear.
Page 610
3. Apply the specified fluid to the entire surface of the rack bushing oil seal. Recommended fluid : PSF-3 4. Install the oil seal (A) in the rack bushing (B). 5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing. 6.
Page 611
8. Push in the rack stopper (A) until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Then, install the circlip while turning the rack stopper. The circlip should not be visible through the notched hole of the rack housing. 9.
Page 612
and O-ring in the gear box(B). 12. Install the rack support yoke (A), rack supportspring (B), yoke plug (C) and lock nut (D) in the ordershown in the illustration. Apply semi-drying sealantto the threaded section of the yoke plug before installation. 13.
Page 613
15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod. Recommended grease : Silicone grease 16. Install the new attaching band to the bellows. When the bellows are installed, a new band must be used. 17.
Page 615
Power Steering Hoses…
Page 616
2007 > 2.7L V6 GASOLINE > COMPONENTS [Diesel] [Gasoline]…
Page 618
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.
Page 619
[Diesel] [Gasoline] 5. Remove the bracket of the return tube and hose. [Diesel] [Gasoline]…
Page 620
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)
Page 621
Power Steering Oil Pump…
Page 622
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 623
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the pressure tube (A) from the oil pump by loosening the eye bolt. Tightening torque Nm (kgf-m, lb-ft): 65 ~ 75 (6.5 ~ 7.5, 47 ~ 54) 2. Disconnect the suction hose (B) from the suction pipe. [Diesel] [Gasoline] 3.
Page 624
Tightening torque Nm (kgf.m lb-ft): 38 ~ 47 (3.8 ~ 4.7, 27 ~ 34) [Diesel] Tightening torque Nm (kgf.m lb-ft): 35 ~ 50 (3.5 ~ 5.0, 25 ~ 36) [Gasoline] Be careful not to spill fluid from the power steering oil pump. INSTALLATION 1.
Page 625
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.
Page 626
4. Remove the cam ring. 5. Remove the oil pump side plate (A). 6. Remove the inner and outer O-ring (A). When assembling, use a new gasket and O-ring.
Page 627
7. Mount the pump in a vise and remove the pulley (A) nut and the spring washer. 8. After removing the snap ring (A) of the shaft with snap ring pliers, remove the dust spacer. 9. Tap the rotor side of the shaft slightly with a plastic hammer (A) to remove the shaft (B). 10.
Page 628
12. Remove the O-ring from the connector. Do not disassemble the flow control valve. INSPECTION 1. Check that the flow control valve is not bent. 2. Check the shaft for wear and damage. 3. Check the V belt for wear and deterioration. 4.
Page 629
3. After inserting the shaft assembly into the pump body, install the dust spacer and snap ring (A). 4. Install the pump pulley(A). Tightening torque : 55 ~ 69 Nm (5.5 ~ 6.9 kgf·m, 39.8 ~ 49.9 lb-ft) 5. Install the inner O-ring and outer O-ring (A).
Page 630
6. Install the oil pump side plate (A). 7. After inserting the lock pin into the groove of the front housing, install the camring (A) attending to the direction. 8. Install the rotor and the vanes. 9. Install the gasket and oil pump cover assembly (A).
Page 631
10. Install the O-ring (A) and the suction pipe mounting bolt. Tightening torque : 13.6 ~ 18.4 Nm (1.36 ~ 1.84 kgf·m, 9.84 ~ 13.3 lb-ft)
Page 632
Variouble Rack Stroke…
Page 633
2007 > 2.7L V6 GASOLINE > Description The VRS (Variable Rack Stroke) is the system that controls the rack stroke using the operating unit installed on both ends of the gear box. Normally the VRS system keeps switching OFF and the rack stroke stays increased, so the vehicle’s turning radius becomes reduced.
Page 635
2007 > 2.7L V6 GASOLINE > TROUBLE SHOOTING Symptom Probable cause Remedy a. Inspect the VRS operating unit. a. VRS operating unit There is no change made in rack b. Check Input/ output signal of the stroke even though turning the VRS b.
Page 636
Supplied power Standard value VRS CM failure 8 V or above Below 8 V 12 V 11 V or above Below 11 V 15 V 14 V or above Below 14 V ▶ Inspect connection of connectors and harness for the VRS system. ▶…
Page 637
VRS Control Unit…
Page 638
2007 > 2.7L V6 GASOLINE > Description The VRS control module (A) controls the DC motor in the VRS operating unit according to signal of the VRS switch (ON or OFF) and is mounted behind the center fascia.
Page 639
VRS Operating Unit…
Page 640
2007 > 2.7L V6 GASOLINE > Description The VRS operating unit installed on both ends of the steering gear box can change the rack stoke by changing angle of the gear stopper.
Page 641
VRS Switch…
Page 642
2007 > 2.7L V6 GASOLINE > Description The VRS switch (A) is located on the cluster fascia panel as shown in the illustration and «VRS» is printed on the VRS switch.
Page 643
CHAPTER 11: Heating, Ventilation, Air Conditioning…
Page 644
Air Conditioning System…
Page 645
2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Tool Illustration (Number and name) 09977-29000 Removal and installation of the Disc & hub assembly bolt disc & hub assembly bolt remover…
Page 646
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant charge, air flow or compressor. Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem.
Page 647
2007 > 2.7L V6 GASOLINE > SPECIFICATION Air conditioner Item Specification Type VS (Variable capacity) Oil type & Capacity ND-OIL8 (PAG), 120 ± 10cc Compressor Pulley type L5OS-TYPE Displacement 180cc/rev Condenser Heat rejection 14,000 ± 5% kcal/hr ON: 370 ± 2.8 (26.0 ± 0.2) High [psi(kg/cm²)] OFF: 455 ±…
Page 648
Air Conditioning System…
Page 649
2007 > 2.7L V6 GASOLINE > INSTRUCTIONS WHEN HANDLING REFRIGERANT 1. R-134a liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves. 2. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the refrigerant splashes into your eyes, wash them with clean water immediately.
Page 650
FLANGE WITH GUIDE PIN Check the new O-ring for damage (use only the specified) and lubricate it using compressor oil. Tighten the nut to specified torque. Tightening torque [ N.m (kg.m, lbf.ft) ] Size General bolt, nut 5-6(0.5 — 0.6, 3.6 — 4.3) 9-11(0.9 — 1.1, 6.5 — 7.9)a 12-14(1.2 — 1.4, 8.7 — 10) 20 — 26 (2.0 — 2.6, 14 — 18)
Page 651
2007 > 2.7L V6 GASOLINE > REFRIGERATION CYCLE…
Page 652
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION INDEX ENGINE ROOM INTERIOR…
Page 654
2007 > 2.7L V6 GASOLINE > REFRIGERANT SYSTEM SERVICE BASICS REFRIGERANT RECOVERY Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove HFC- 134a(R-134a) from the air conditioning system. a. Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. b.
Page 655
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. 1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be evacuated using an R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.) 2.
Page 656
In order to use the leak detector properly, read the manual supplied by the manufacturer. If a gas leak is detected, proceed as follows: 1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage with a leak detector (A).
Page 657
Compressor…
Page 658
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION COMPONENTS…
Page 660
2007 > 2.7L V6 GASOLINE > REMOVAL 1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off. 2. Disconnect the negative cable from the battery. 3.
Page 661
volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should drain from the new compressor (through the suction fitting). b. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
Page 662
4. Check operation of the magnetic clutch.Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition. DISASSEMBLY 1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub assembly bolt remover;…
Page 663
4. Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor. 5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items : a.
Page 664
Compressor oil…
Page 665
2007 > 2.7L V6 GASOLINE > INSPECTION Oil Specification 1. The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system requires mineral compressor oil. The two oils must never be mixed. 2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor.
Page 666
Condenser…
Page 667
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 668
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with compressed air. If bent, gently bend them using a screwdriver or pliers. 2. Check the condenser connections for leakage, and repair or replace it, if required. REPLACEMENT CONDENSER ASSEMBLY 1.
Page 669
2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged bottom cap filter. 3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap. 4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed to air for use.
Page 670
Refrigerant Line…
Page 671
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 672
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Discharge refrigerant from refrigeration system (Refer to HA-8). 2. Replace faulty tube or hose. Cap the open fittings immediately to keep moisture or dirt out of the system. 3. Tighten joint of bolt or nut to specified torque. Connections should not be torque tighter than the specified torque.
Page 673
A/C Pressure Transducer…
Page 674
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 675
2007 > 2.7L V6 GASOLINE > DESCRIPTION A/C pressure transducer convert the pressure value of high pressure line into voltage value after measure it. By converted voltage value, engine ECM controls cooling fan by operating it high speed or low speed. Engine ECM stop the operation of compressor when the temperature of refrigerant line is so high or so low irregularly to optimize air conditioning system.
Page 676
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals. 2. Inspect the voltage value whether it is sufficient to be regular value or not. Vout = Vdd(0.025 * P + 0.1) [kgf/cm²G] Vout = Vdd(0.001758 * P + 0.074162) [PSIA] 3.
Page 677
Evaporator Temperature Sensor…
Page 678
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 679
2007 > 2.7L V6 GASOLINE > DESCRIPTION The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay power in order to prevent evaporator freezing by excessive cooling.
Page 680
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF» 2. Disconnect evaporator temperature sensor. 3. Using the multi-tester, Measure resistance between terminal «1» and «2» of evaporator temperature sensor. Specification Evaporator core temperature [°C(°F)] Resistance [kΩ] -10(14) 13.6 0(32) 10(50) 15(59) 30(86)
Page 681
3. Disconnect the evaporator sensor connector (A). 4. Loosen 2 screws and then remove the evaporator sensor cover(B). 5. Remove the evaporator sensor. Take care that evaporator core pins are not bent. 6. Installation is the reverse order of removal.
Page 682
In-car Sensor…
Page 683
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 684
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. In-car air temperature sensor is located at the center facia lower panel. 2. The sensor contains a thermistor which measures the temperature of the inside. The signal decided by the resistance value which changes in accordance with perceived inside temperature, is delivered to heater control unit and according to this signal the control unit regulates incar temperature to intended value.
Page 685
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4 terminals. Specification Temperature [°C(°F)] Resistance between terminals 2and 4 (kΩ) 0 (32) 97.83 ±…
Page 686
Photo Sensor…
Page 687
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 688
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The photo sensor (A) is located at the center of defrost nozzle. 2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light receiving portion, generates an electromotive force in proportion to the amount of radiation received which is transferred to the automatic temperature control module so that the solar radiation compensation will be performed.
Page 689
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Using the scan tool. 3. Emit intensive light toward photo sensor using a lamp, and check the output voltage change. 4. The voltage will rise with higher intensive light and reduce with lower intensive light. REPLACEMENT 1.
Page 690
Water Temperature Sensor…
Page 691
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 692
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Water temperature sensor is located at the heater unit. 2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the heater before the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower motor speed until coolant temperature reaches the threshold value.
Page 693
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Using the multi-tester, Measure resistance between terminal «1» and «2» of water temperature sensor. Specification Coolant temperature [°C(°F)] Resistance (kΩ) Voltage (V) -10(14) 55.85 ± 3% 4.24 ± 3% 0(32) 32.91 ±…
Page 694
4. Installation is the reverse order of removal. Take care that wire of water temperature sensor is not to be damaged…
Page 695
Ambient Sensor…
Page 696
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 697
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is a negative type thermistor; resistance will increase with lower temperature, and decrease with higher temperatures. 2.
Page 698
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF» 2. Disconnect ambient temperature sensor. 3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing of the ambient temperature. Specification Ambient temperature [°C(°F)] Resistance between terminals 1and 2 (kΩ) -10(14) 164 ±…
Page 699
Air Quality Sensor…
Page 700
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 701
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. A.Q.S is located at center support in front of the engine radiator, and detects hazardous elements in ambient air providing output signal to control. 2. It will detect sulfurous acid gas, carbon dioxide, carbon monoxide, hydrocarbon and allergen.
Page 702
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Using the scan tool. 3. Check the output voltage of AQS between terminals 2 and 3. Specification Condition Output signal Fresh/recirculation Normal condition 4 ~ 5V Fresh Hazardous gas detection 0 ~ 1V Recirculation 4.
Page 703
Humidity Sensor…
Page 704
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 705
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Humidity sensor is located at the lower crush pad and detected in-car humidity for in-car humidity control. 2. If ambient air temperature or in-car humidity is outside certain range, it will turn on A/C to control in-car humidity preventing in car fogging.
Page 706
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Using the scan tool. 3. Check the frequency of humidity sensor between terminals 2 and 3. Humidity (%) Frequency between terminals 2and 3 (Hz) 6976 ± 5% 6728 ± 5% 6600 ±…
Page 707
Heater…
Page 708
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION COMPONENTS…
Page 713
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Disconnect the negative (-) battery terminal. 2. Recover the refrigerant with a recovery/ recycling/ charging station. (Refer to HA-8) 3. When the engine is cool, drain the engine coolant from the radiator. 4.
Page 714
10. Remove the blower unit (B) from heater unit after loosening 2 screws. 11. Remove the self-tapping screws (A) and remove the PTC heater unit (B) or cover. (In case of PTC heater) 12. Remove the heater core (B) after remove the cover (A). 13.
Page 715
14. Remove the evaporator core(A). 15. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core. 16. Install the heater core in the reverse order of removal. 17. Installation is the reverse order of removal, and note these items : a.
Page 716
Temperature Control Actuator…
Page 717
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 718
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Heater unit includes mode control actuator and temperature control actuator. 2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature will be regulated by the hot/cold air ratio decided by position of temperature door…
Page 719
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF» 2. Disconnect the connector of temperature control actuator. 3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 1 and grounding terminal 2. Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
Page 720
1. Disconnect the negative (-) battery terminal. 2. Remove the driver’s crush pad lower panel (Refer to BD group). 3. Disconnect the temperature control actuator connector (A) after removing the air duct. 4. Loosen the mounting screw and then remove the temperature control actuator (B). [Passenger’s] [Driver’s] 5.
Page 721
Model Control Actuator…
Page 722
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 723
2007 > 2.7L V6 GASOLINE > DESCRIPTION The mode control actuator is located at the heater unit. It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of vent→ B/L → floor → mix.
Page 724
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF» 2. Disconnect the connector of mode control actuator. 3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 1 and grounding terminal 2. 4.
Page 725
[Passenger’s] [Driver’s] 5. Installation is the reverse order of removal.
Page 726
Fuel Fired Heater…
Page 727
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 728
2007 > 2.7L V6 GASOLINE > DESCRIPTION The fuel fired heater has been applied to the diesel engine (CRDi) to increase heating capability by using diesel only in cold weather a. Follow the procedures specified in this bulletin during service or it may cause personal injury. b.
Page 729
3. The two coolant temperature sensors are installed to the heater inner. The sensor valves determine heater operation. 4. One of the temperature sensors functions to prevent the heater from overheating. If the sensor temperature valve exceeds 125°C, the fuel will be cut and the heater will be deactivated by the determination of the overheating of the heater.
Page 730
When the cleaning process is over, the operation of the heater is stopped. The time for cleaning when the engine is turned off during the operation of the heater at full load is about 175 seconds. About 100 seconds are required to conduct the cleaning of the heater at half load condition. The operating sound of cleaning the heater is heard from the outside of the heater after turning the engine off and this is a normal process of operation…
Page 731
2007 > 2.7L V6 GASOLINE > INSPECTION OPERATION TEST Fuel-fired heater operation test by force using Hi-Scan 1. Start the engine. 2. Connect the Hi-Scan to the vehicle. 3. Select «SORENTO» and then select «FUEL FIRED HEATER». 4. Select «04. ACTUATION TEST» mode. 5.
Page 732
Component test 1. Using the Hi-Scan, conduct component test after selecting «FUEL FIRED HEATER» and «ACTUATION TEST» mode. 2. After conducting component test, perform self-diagnosis test. 3. It is recommended to conduct the fuel fired heater system test after completing the component test. 4.
Page 733
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING SYMPTOM REMEDY Check fuel system on vehicle. Check the fuel supply line in the fuel fired heater for fuel leaking and Fuel smell fuel hose for twisting or clogging. If none of above is affected, there is likelihood of fuel leaking from the heater inner.
Page 734
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS ITEM OPERATION STATE SPECIFICATION Full load 5.0kw Heater discharge Half load 2.5kw Full load Diesel Full load 0.63 l/h Fuel consumption Half load 0.32 l/h Rated voltage 12.0V Operation voltage range 9.5V~15.0V Full load 37w(Normal)
Page 735
Positive Temperature Coefficient Heater…
Page 736
2007 > 2.7L V6 GASOLINE > DESCRIPTION PTC (Positive Temperature Coefficient) heater (A) is an electric heater using a PTC element as an auxiliary heating device that supplements deficiency of interior heat source in highly effective diesel engine (U engine). An electric heater heats up the interior by directly heating the air that passes through the heater.
Page 737
2007 > 2.7L V6 GASOLINE > INSPECTION Inspect the PTC operation by confirmation logic as below. 1. Entering method (1) Set the floor mode, maximum heating (2) Turn off the blower switch (3) Press the intake button more than 5 times. (4) Indicator of entire button is flashed with an interval of 0.5 seconds continuously (Manual).
Page 738
Rear Heater…
Page 739
Rear Heater Unit…
Page 740
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION COMPONENTS…
Page 743
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Disconnect the negative(-) battery terminal. 2. Recover the refrigerant with a recover/ recycling/ charging station. 3. When the engine is cool, drain the engine coolant from the radiator. 4. Remove luggage side trim(Refer to BD-). 5.
Page 744
9. Remove the heater core mouting cover(A), after loosening the screw. 10. Remove the heater core(A). 11. Installation is the reverse order of removal.
Page 745
Rear Blower Unit…
Page 746
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Connect the battery voltage and check the blower motor rotation. 2. If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for proper operation. 3. If the problem is corrected, replace the blower motor. REPLACEMENT 1.
Page 747
Rear Temperature Control Actuator…
Page 748
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Heater unit includes mode control actuator and temperature control actuator. 2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature will be regulated by the hot/cold air ratio decided by position of temperature door.
Page 749
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF». 2. Disconnect the connector of temperature control actuator. 3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 1 and grounding terminal 2. Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
Page 750
Rear Mode Control Actuator…
Page 751
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF». 2. Disconnect the connector of mode control actuator. 3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 1 and grounding terminal 2. 4.
Page 752
Rear Power Mosfet…
Page 753
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON». 2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2. 3. Select the control switch to raise voltage until high speed. Voltage Manual 1 STEP 4.5 ±…
Page 754
Rear Control Panel…
Page 755
2007 > 2.7L V6 GASOLINE > COMPONENT Tail lamp (ILL+) IGN 2 Rear temp S/W Rear temp S/W (VENT) Rear temp S/W (B/L)
Page 756
Rear temp S/W (FLOOR) Rhostat (ILL-) Sensor Ref (+5V) Sensor ground Rear mode IND (VENT) Rear mode IND (B/L) Rear mode IND (FLOOR) Rear blower S/W…
Page 757
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Remove the rear control panel(A) and then dissconnect the rear control panel connector(B). 2. Installation is the reverse order of removal.
Page 758
Blower…
Page 759
Blower Unit…
Page 760
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION COMPONENTS…
Page 762
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Disconnect the negative (-) battery terminal. 2. Remove the crush pad.(Refer to BD group) 3. Disconnect the connectors from the intake actuator, the blower motor and power mosfet. 4. Remove the cowl cross bar assembly.(Refer to BD group) 5.
Page 763
Blower Motor…
Page 764
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 765
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Connect the battery voltage and check the blower motor rotation. 2. If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for proper operation. 3. If the problem is corrected, replace the blower motor. REPLACEMENT 1.
Page 766
Blower Relay…
Page 767
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 768
2007 > 2.7L V6 GASOLINE > INSPECTION 1. There should be continuity between the NO.1 in the A and NO.10 in the B terminals when power and ground are connected to the NO.7 and NO.13 in the A terminals. (Passenger compartment relay box) 2.
Page 769
Power Mosfet…
Page 770
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 771
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «ON» 2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2. 3. Select the control switch to raise voltage until high speed. Specification Motor Voltage Manual First speed…
Page 772
4. Installation is the reverse order of removal.
Page 773
Climate Control Air Filtar…
Page 774
2007 > 2.7L V6 GASOLINE > DESCRIPTION This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as conventional dust filter to ensure comfortable interior environment.
Page 775
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Open the glove box (B). Lower the glove box down completely by removing the glove box stopper (A) to the glove box. 2. Remove the filter cover (A) with pushing the knob. 3.
Page 776
Intake Actuator…
Page 777
2007 > 2.7L V6 GASOLINE > COMPONENT LOCATION…
Page 778
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The intake actuator is located at the blower unit. 2. It regulates the intake door by signal from control unit. 3. Pressing the intake selection switch will shift between recirculation and fresh air modes.
Page 779
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Ignition «OFF» 2. Disconnect the intake actuator connector. 3. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and grounding terminal 4. 4. Verify that the intake actuator operates to the fresh position when connecting in the reverse. 5.
Page 780
Controller…
Page 781
MANUAL…
Page 782
2007 > 2.7L V6 GASOLINE > COMPONENT CONNECTOR PIN FUNCTION PIN NO. Function PIN NO. Function BATTERY IGN 2 POWER MOSFET (GATE) — REAR POWER MOSFET (DRAIN) — TAIL LAMP (ILL+) REAR REAR TEMP ACTUATOR (COOL) REAR TEMP ACTUATOR SENSOR GND (WARM)
Page 783
Connector B REAR TEMP ACTUATOR SENSOR POWER (+5V) (F/B) REAR TEMP SWITCH REAR MODE ACTUATOR HAZARD SEIECT (VENT) REAR MODE ACTUATOR (FLOOR) REAR MODE ACTUATOR (F/B) DRIVE’S TEMP ACTUATOR BLOWER MOTOR (+) (COOL) DRIVE’S TEMP ACTUATOR GROUND (WARM) RHEOSTAT (ILL-) DRIVE’S TEMP ACTUATOR (F/B) Connector A DRIVE’S MODE ACTUATOR…
Page 784
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Disconnect the negative (-) battery terminal. 2. Remove the center air vent. (Refer to BD group) 3. Remove the heater & A/C controller (A) after loosening 4 screws. 4. Remove the heater & A/C controller (A). 5.
Page 785
FULL AUTOMATIC…
Page 786
2007 > 2.7L V6 GASOLINE > COMPONENT CONNECTOR PIN FUNCTION PIN NO. Function PIN NO. Function BATTERY IGN 2 POWER MOSFET (GATE) — REAR POWER MOSFET (DRAIN) — TAIL LAMP (ILL+) REAR REAR TEMP ACTUATOR (COOL) REAR TEMP ACTUATOR SENSOR GND (WARM)
Page 787
Connector B REAR TEMP ACTUATOR SENSOR POWER (+5V) (F/B) REAR TEMP SWITCH REAR MODE ACTUATOR HAZARD SEIECT (VENT) REAR MODE ACTUATOR (FLOOR) REAR MODE ACTUATOR (F/B) DRIVE’S TEMP ACTUATOR BLOWER MOTOR (+) (COOL) DRIVE’S TEMP ACTUATOR GROUND (WARM) RHEOSTAT (ILL-) DRIVE’S TEMP ACTUATOR (F/B) Connector A DRIVE’S MODE ACTUATOR…
Page 788
2007 > 2.7L V6 GASOLINE > REPLACEMENT 1. Disconnect the negative (-) battery terminal. 2. Remove the center air vent. (Refer to BD group) 3. Remove the heater & A/C controller (A) after loosening 4 screws. 4. Remove the heater & A/C controller (A). 5.
Page 789
CHAPTER 12: Restraint…
Page 790
General information…
Page 791
2007 > 2.7L V6 GASOLINE > Precautions General Precautions Please read the following precautions carefully before performing the airbag system service. Observe the instructions described in this manual, or the airbags could accidentally deploy and cause damage or injuries. a. Except when performing electrical inspections, always turn the ignition switch OFF and disconnect the negative cable from the battery, and wait at least three minutes before beginning work.
Page 792
c. Store the removed airbag on secure, flat surface away from any high heat source (exceeding 85°C/185°F). d. Never perform electrical inspections to the airbags, such as measuring resistance. e. Do not position yourself in front of the airbag assembly during removal, inspection, or replacement. f.
Page 793
b. Be sure to install the harness wires so that they are not pinched, or interfere with other parts. c. Make sure all SRS ground locations are clean, and grounds are securely fastened for optimum metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to diagnose. Precautions for Electrical Inspections a.
Page 794
Using improper tools could cause an error in inspection due to poor metal contact. Airbag Connector Connecting Hold both connector halves and press firmly until the projection (C) of the sleeve-side connector clicks to lock.
Page 795
2007 > 2.7L V6 GASOLINE > General The supplemental restraint system (SRS) is designed to supplement the seat belt to help reduce the risk or severity of injury to the driver and passenger by activating and deploying the driver, passenger, side airbag and belt pretensioner in certain frontal or side collisions.
Page 796
2007 > 2.7L V6 GASOLINE > SPECIAL SERVICE TOOLS Tool(Number and Name) Illustration Deployment tool Airbag deployment tool 0957A-34100A Deployment adapter Use with deployment tool. 0957A-3F100 (PAB, SAB) Deployment adapter Use with deployment tool. 0957A-38500 (DAB, PAB, CAB, BPT) Dummy Simulator to check the resistance of 0957A-38200 each wiring harness…
Page 797
2007 > 2.7L V6 GASOLINE > WARNING LAMP ACTIVATION WARNING LAMP BEHAVIOR AFTER IGNITION ON As soon as the operating voltage is applied to the SRSCM ignition input, the SRSCM activates the warning lamp for a bulb check. The lamp shall turn on for 6 seconds during the initialization phase and be turned off afterward. However, in order to indicate the driver, the warning lamp shall turn on for 6 seconds and off for one second then on continuously after the operating voltage is applied if any active fault exists.
Page 798
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 799
COMPONENTS LOCATION DRIVER AIRBAG (DAB) / PASSENGER AIRBAG (PAB)
Page 800
SIDE AIRBAG (SAB) SEAT BELT PRETENSIONER (BPT)
Page 801
SEAT BELT BUCKLE PRETENSIONER (BUPT) SIDE IMPACT SENSOR (SIS)
Page 802
FRONT IMPACT SENSOR (FIS)
Page 803
SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE (SRSCM)
Page 804
2007 > 2.7L V6 GASOLINE > COMPONENT REPLACEMENT AFTER DEPLOYMENT Before doing any SRS repairs, use the Hi-Scan Pro to check for DTCs. Refer to the Diagnostic Trouble Code list for repairing of the related DTCs. When the front airbag(s) deployed after a collision, replace the following items. a.
Page 805
2007 > 2.7L V6 GASOLINE > SPECIFICATION Item Resistance (Ω) Driver Airbag (DAB) 1.6 ~ 4.7 Passenger Airbag (PAB) 1.6 ~ 4.7 Side Airbag (SAB) 1.6 ~ 4.7 Curtain Airbag (CAB) 1.6 ~ 4.7 Seat Belt Pretensioner (BPT) 1.6 ~ 4.7 Seat Belt Buckle Pretensioner (BUPT) 1.6 ~ 4.7 TIGHTENING TORQUES…
Page 806
Supplemental Restraint System Control Module (SRSCM)
Page 807
2007 > 2.7L V6 GASOLINE > CIRCUIT DIAGRAM(1) CIRCUIT DIAGRAM(2)
Page 808
SRSCM CONNECTOR TERMINAL SRSCM HARNESS CONNECTOR…
Page 809
DIAGNOSTIC TROUBLE CODES (DTC) FAULT DESCRIPTION PAGE B1101 Battery Voltage too High B1102 Battery Voltage too Low B1328 Front Impact Sensor [Driver] Defect B1329 Front Impact Sensor [Driver] Communication Error B1333 Front Impact Sensor [Passenger] Defect B1334 Front Impact Sensor [Passenger] Communication Error B1346 Driver Airbag Resistance too High B1347…
Page 810
B1348 Driver Airbag Circuit Short to Ground B1349 Driver Airbag Circuit Short to Battery B1352 Passenger Airbag Resistance too High B1353 Passenger Airbag Resistance too Low B1354 Passenger Airbag Circuit Short to Ground B1355 Passenger Airbag Circuit Short to Battery B1361 Seat Belt Pretensioner [Front-Driver] Resistance too High B1362…
Page 811
B1529 Passenger Airbag Deactivation Switch Defect B1530 Passenger Airbag Deactivation Switch Instability B1620 Supplemental Restraint System Control Module Internal Fault (Replace SRSCM) B1650 Crash Recorded — Frontal (Replace SRSCM) B1651 Crash Recorded — Driver Side (Replace SRSCM) B1652 Crash Recorded — Passenger Side (Replace SRSCM) B1655 Crash Recorded — Passenger Side with PAB inhibited (Replace SRSCM) B1657…
Page 812
2007 > 2.7L V6 GASOLINE > DESCRIPTION HI-SCAN CHECK 1. Turn the ignition switch off. 2. Connect the Hi-Scan Pro connector to the data link connector located under the crash pad. 3. Turn the ignition switch on and power on the Hi-Scan Pro. 4.
Page 813
TERMINAL & CONNECTOR INSPECTION Be sure to perform «TERMINAL & CONNECTOR INSPECTION» before doing «INSPECTION PROCEDURE» for troubleshooting of each DTC. 1. Visually inspect all connectors related to the affected circuit for damage and secure connection. 2. Inspect terminals for damage and corrosion. Avoid damaging connectors during the inspection process.
Page 814
5. Disconnect the SRSCM connector. CHECKING OF SHORT OR OPEN CIRCUIT Refer to the following tips for checking of short or open circuit. 1. Shorting bar is located between the upper and lower side pins of SRSCM connector. 2. When checking the short circuit shorting bar must be opened. Use a plastic clip to put into as a shorting bar opener for disconnecting shorting bar.
Page 815
SRS Control Module (SRSCM)
Page 816
2007 > 2.7L V6 GASOLINE > DESCRIPTION The primary purpose of the SRSCM (Supplemental Restraints System Control Module) is to discriminate between an event that warrants restraint system deployment and an event that does not. The SRSCM must decide whether to deploy the restraint system or not.
Page 817
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 818
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the negative (-) cable from battery and wait for at least three minutes. 2. Remove ignition key from the vehicle. 3. Disconnect the DAB, PAB, SAB, CAB and BPT connectors. 4. Remove the floor console and heater ducts. (Refer to BD group) 5.
Page 819
5. Install the heater ducts and floor console. (Refer to BD group) 6. Connect the DAB, PAB, SAB, CAB and BPT connectors. 7. Reconnect the battery negative cable. 8. After installing the SRSCM, 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.
Page 820
Front Impact Sensor (FIS)
Page 821
2007 > 2.7L V6 GASOLINE > DESCRIPTION The front impact sensors (FIS) are installed in the side member. They are remote sensors that detect acceleration due to a collision at their mounting locations. The primary purpose of the Front Impact Sensor (FIS) is to provide an indication of a collision.
Page 822
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 823
2007 > 2.7L V6 GASOLINE > removal a. Removal of the airbag must be performed according to the precautions/ procedures described previously. b. Before disconnecting the front impact sensor connector, disconnect the front airbag connector(s). c. Do not turn the ignition switch ON and do not connect the battery cable while replacing the front impact sensor.
Page 824
Side Impact Sensor (SIS)
Page 825
2007 > 2.7L V6 GASOLINE > DESCRIPTION The Side Impact Sensor (SIS) system consists of two front SIS which are installed inside the Center Pillar (LH and RH) and two rear SIS which are installed in the rear pillar (LH and RH). They are remote sensors that detect acceleration due to collision at their mounting locations.
Page 826
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 827
2007 > 2.7L V6 GASOLINE > REMOVAL FRONT SIDE IMPACT SENSOR a. Removal of the airbag must be performed according to the precautions/procedures described previously. b. Before disconnecting the side impact sensor connector(s), disconnect the side airbag connector(s). c. Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor.
Page 828
a. Ensure that the harness is installed and routed properly to prevent damage to the wiring. b. Do not turn the ignition switch ON and do not connect the battery cable while replacing the side impact sensor. 1. Install the new Side Impact Sensor with the bolt then connect the SRS harness connector to the Side Impact Sensor.
Page 829
Airbag Module…
Page 830
2007 > 2.7L V6 GASOLINE > AIRBAG DISPOSAL SPECIAL TOOL REQUIRED Before scrapping any airbags or side airbags (including those in a whole vehicle to be scrapped), the airbags or side airbags must be deployed. If the vehicle is still within the warranty period, before deploying the airbags or side airbags, the Technical Manager must give approval and/or special instruction.
Page 831
DEPLOYING THE AIRBAG OUT OF THE VEHICLE If an intact airbag has been removed from a scrapped vehicle, or has been found defective or damage during transit, storage or service, it should be deployed as follows : 1. Position the airbag face up, outdoors on flat ground at least thirty feet (10meters) from any obstacles or people. DISPOSAL OF DAMAGED AIRBAG 1.
Page 832
Drive Airbag (DAB) Module Clock Spring…
Page 833
2007 > 2.7L V6 GASOLINE > DESCRIPTION Driver Airbag (DAB) is installed in steering wheel and electrically connected to SRSCM via clockspring. It protects the driver from danger by deploying a bag when frontal crash occurs. The SRSCM determines deployment of Driver Airbag (DAB).
Page 834
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 835
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.
Page 836
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.
Page 837
4. Check airbag inflator case for dents, cracks or deformities. 5. Install the airbag module to the steering wheel to check for fit or alignment with the wheel. Clockspring 1. If, as a result of the following checks, even one abnormal point is discovered, replace the clock spring with a new one.
Page 838
Passenger Airbag (PAB) Module…
Page 839
2007 > 2.7L V6 GASOLINE > DESCRIPTION The passenger Airbag (PAB) is installed inside the crash pad and protects the front passenger in the event of a frontal crash. The SRSCM determines if and when to deploy the PAB. Never attempt to measure the circuit resistance of the airbag module (squib) even if you are using the specified tester.
Page 840
2007 > 2.7L V6 GASOLINE > components…
Page 841
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the battery negative cable and wait for at least three minutes before beginning work. 2. Remove the glove box. (Refer to BD group) 3. Disconnect the PAB connector and remove the PAB mounting bolts. (Refer to BD group) 4.
Page 842
INSTALLATION 1. Disconnect the negative (-) cable from battery and wait for at least three minutes. 2. Remove ignition key from the vehicle. 3. Place a Passenger Airbag (PAB) on the crash pad and tighten the Passenger Airbag (PAB) mounting nuts. Tightening Torque : 0.7 ~ 0.8 kgf.m (7.0 ~ 8.0 N.m, 5.2 ~ 5.9 lb.ft) 4.
Page 843
Curtain Airbag (CAB) Module…
Page 844
2007 > 2.7L V6 GASOLINE > DESCRIPTION Curtain airbags are installed inside the headliner (LH and RH) and protect the driver and passenger from danger when side crash occurs. The SRSCM determines deployment of curtain airbag by using side impact sensor (SIS) signal. Never attempt to measure the circuit resistance of the airbag module even if you are using the specified tester.
Page 845
2007 > 2.7L V6 GASOLINE > components…
Page 846
2007 > 2.7L V6 GASOLINE > removal 1. Disconnect the battery negative cable and wait for at least 3 minutes before beginning work. 2. Remove the following parts. (Refer to BD group) a. Interior trim b. Headlining 3. Disconnect the Curtain Airbag harness connector (front & rear). 4.
Page 847
Side Airbag (SAB) Module…
Page 848
2007 > 2.7L V6 GASOLINE > DESCRIPTION The two Side Airbags (SAB) are installed inside the driver and passenger seat and protects the driver and front passenger from danger when side crash occurs. The SRSCM determines deployment of side airbag by using Side Impact Sensor (SIS) signal.
Page 849
2007 > 2.7L V6 GASOLINE > components…
Page 850
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the battery negative cable and wait at least 3 minutes before beginning work. 2. Remove the front seat assambly.(Refer to BD group) 3. Remove the seatback cover.(Refer to BD group) When the side airbag depoyed after a collision, replace the seatback as an assembly. 4.
Page 851
4. Install the new seatback cover.(Refer to BD group) 5. Install the seat assembly, then connect the Side Airbag (SAB) harness connector. 6. Recline and slide the front seat forward fully, make sure the harness wires are not pinched or interfering with other parts.
Page 852
Seat Belt Pretensioner (BPT)
Page 853
2007 > 2.7L V6 GASOLINE > DESCRIPTION The Seat Belt Pretensioners (BPT) are installed inside Center Pillar (LH & RH). When a vehicle crashes with a certain degree of frontal impact, the pretensioner seat belt helps to reduce the severity of injury to the front seat occupants by retracting the seat belt webbing.
Page 854
2007 > 2.7L V6 GASOLINE > components…
Page 855
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. 2. Remove the door scuff trim. (Refer to BD group) 3. Remove the center pillar trim. (Refer to BD group) 4.
Page 856
Seat Belt Buckle Pretensioner…
Page 857
2007 > 2.7L V6 GASOLINE > DESCRIPTION The Seat Belt Buckle Pretensioners (BUPT) are installed in the right side of the driver seat and the left side of the passenger seat. When a vehicle crashes with a certain degree of frontal impact, the seat belt buckle pretensioner helps to reduce the severity of injury to the front seat occupants by retracting the seat belt buckle.
Page 858
2007 > 2.7L V6 GASOLINE > components…
Page 859
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Disconnect the battery negative cable, and wait for at least three minutes before beginning work. 2. Remove the front seat assembly. (Refer to BD group) 3. Loosen the Seat Belt Buckle Pretensioner mounting bolt and remove the Seat Belt Buckle Pretensioner. INSTALLATION 1.
Page 860
CHAPTER 13: Brake System…
Page 861
General information…
Page 862
2007 > 2.7L V6 GASOLINE > SPECIAL TOOL Tool(Number and Name) Illustration 09581-11000 Spreading the front disc brake piston Piston expander…
Page 863
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Symptom Suspect Area Reference Lower pedal or repair a. Brake system (Fluid leaks) spongy pedal air·bleed b. Brake system (Air in) replace c. Piston seals (Worn or damaged) adjust d. Rear brake shoe clearance(Out of adjustment) replace e.
Page 864
replace e. master cylinder cap seal replace f. damaged brake lines Brake chatter is usually caused by loose or worn components, or glazed or burnt linings. Rotors with hard spots can also contribute to Brake Chatter brake chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
Page 865
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS Item Specification Master cylinder · Type Tandem type · I.D. mm(in) 26.99/(1.063) · Piston stroke mm(in) 30(1.18) · Fluid level warning sensor Provided Brake booster · Type 8 + 9 in Tandem · Boosting ratio 9.0 : 1 Front brake(Disc) ·…
Page 866
TIGHTENING TORQUE Items kgf.m lb-ft Master cylinder to booster mounting nut 8 ~ 12 0.8 ~ 1.2 5.8 ~ 8.7 Brake booster mounting nut 13 ~ 16 1.3 ~ 1.6 9.4 ~ 11.6 Bleeder screw 7 ~ 13 0.7 ~ 1.3 5.06 ~ 9.4 Brake tube nut, brake hose 13 ~ 17…
Page 867
Part Item Standard Value Remark 4 channel 4 System sensor(Solenoid) Motor, valve relay HECU(Hydraulic and Type ·Total control(ABS, intergrated type Electronic Control EBD, TCS, ESP) Unit) Operating voltage 8 V ~ 16 V(DC) -40 ~ 120 °C(-40 ~ Operating temperature 248 °F) Operating voltage 12 V…
Page 868
Brake System…
Page 869
2007 > 2.7L V6 GASOLINE > Operation and Leakage Check Check all of the following items: Component Procedure Brake Booster (A) Check brake operation by applying the brakes during a test drive. If the brakes do not work properly, check the brake booster. Replace the brake booster as an assembly if it does not work properly or if there are signs of leakage.
Page 870
2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is inoperative. 3.
Page 871
[RHD] BRAKE PEDAL BRAKE SWITCH ADJUSTMENT PEDAL HEIGHT 1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until it is no longer touching the brake pedal. 2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center of the pedal pad (D).
Page 872
BRAKE SWITCH CLEARANCE Screw in the brake switch until its plunger is fully depressed (threded end (A) touching the pad (B) on the pedal arm) then brake off the switch 3/4 turn to make 0.5 ~ 1.0 mm(0.0197 ~ 0.0394 in.) of clearance between the brake switch connector.
Page 873
a. If the pad thickness is out of specilfication, left and right pads must be replaced as a complete set. b. When the thickness difference between the left pad and right pad is large, check the sliding condition of the piston and the guide rod. INSPECTION OF REAR DISC BRAKE PAD 1.
Page 874
Brake Booster…
Page 875
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 876
2007 > 2.7L V6 GASOLINE > Removal 1. Disconnect the vacuum hose (A) from the brake booster (B). [LHD] [RHD] 2. Remove the master cylinder (Refer to ‘Master cylinder removal’). 3. Remove the snap pin (A) and clevis pin (B). 4.
Page 877
INSTALLATION 1. Adjust push rod length of the booster, and then install the seal on the booster assembly. Standard length (A): LHD : 112 ± 0.5 mm (4.43 ± 0.019 in.) RHD : 115 ± 0.5 mm (4.53 ± 0.019 in.) [LHD] [RHD] 2.
Page 878
3. Connect the booster push rod and brake pedal with a pin (B) and install a snap clevis pin (A) to the clevis pin (B). Grease the pin before installing the snap pin. Always use a new snap pin. 4. Install the master cylinder. 5.
Page 879
Master Cylinder…
Page 880
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 881
2007 > 2.7L V6 GASOLINE > REMOVAL Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water. 1. Remove air cleaner mounting bolts (B) from the air cleaner mounting bracket and air cleaner body (A).(LHD) 2.
Page 882
5. Remove the brake fluid from the master cylinder reservoir (C) with a syringe. 6. Disconnect the brake lines (A) from the master cylinder. To prevent spills, cover the hose joints with rags or shop towels. 7. Remove the master cylinder mounting nuts (B) and washers. [LHD] [RHD] 8.
Page 883
[RHD] 3. Fill the brake reservoir with the brake fluid and bleed the brake system (Refer to ‘Bleeding of brake system’). DISASSEMBLY 1. Remove the reservoir cap and drain the brake fluid into a suitable container. 2. Remove the fluid level sensor. 3.
Page 884
5. Remove the primary piston assembly (A). 6. Remove the pin (C) with the secondary piston (B) pushed completely using a screwdriver. Remove the secondary piston assembly (B). Do not disassemble the primary and secondary piston assembly. INSPECTION 1. Check the master cylinder bore for rust or scratching. 2.
Page 885
4. Install the retainer ring (A) after installing primary piston assembly. 5. Mount two grommets. 6. Install the reservoir on the cylinder.
Page 886
Brake Line…
Page 887
2007 > 2.7L V6 GASOLINE > COMPONENT…
Page 888
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the brake hose clip (A). 2. Loosen the brake tube (A) nut holding the brake hose (B) nut with a wrench. 3. Remove the brake hose (B). 4. Remove the brake hose connecting bolt (A) from the caliper assembly. INSTALLATION 1.
Page 889
2. Tighten the brake tube (A) nut holding the brake hose (B) nut with a wrench. 3. Install the brake hose clip (A). 4. After installation, breed the air in the brake system. Be careful not to damage the brake hose by sharp edges or tools. INSPECTION a.
Page 890
Brake Pedal…
Page 891
2007 > 2.7L V6 GASOLINE > COMPONENTS COMPONENTS (ADJUSTABLE PEDAL)
Page 893
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the lower crash pad. (Refer to BD group ‘Crash pad’) 2. Remove the brake switch connector. 3. Remove the trans cable (A) in case of the adjustable brake pedal. 4. Remove the mounting bolt(A) of the peal position sensor connector in case of the adjustable brake pedal. 5.
Page 894
3. Install the snap pin. 4. Adjust the brake pedal height and free play. Before connecting trans cable, be sure that position of pivot pin (A) is initializen. 5. Install the stop lamp switch. INSPECTION 1. Check the bushing for wear. 2.
Page 896
Front Disc Brake…
Page 897
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 899
2007 > 2.7L V6 GASOLINE > REMOVAL Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. a. Avoid breathing dust particles. b. Never use on air hose or brush to clean brake assemblies. 1.
Page 900
If you are reusing the pads, always reinstall the brake pads in their original positions to prevent a momentary loss of braking efficiency. 3. Insert the piston in the cylinder using the special tool (09581-11000). 4. Push in the piston (A) so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down.
Page 901
10. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. INSPECTION FRONT BRAKE DISC THICKNESS CHECK 1. Remove all rust and contramination from the surface, and measure the disc thickness at 8 points, at least, of same distance (5mm) front the brake disc outer circle.
Page 902
Brake disc run out Limit : 0.03 mm (0.0012 in.) or less (new one) 2. If the run out of the brake disc exceeds the limit specification, replace the disc, and then measure the run out again. 3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the run out of the brake disc again.
Page 903
Rear Disc Brake…
Page 904
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 905
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Raise the rear of the vehicle and make sure it is securely supported. Remove the rear wheel. 2. Remove the guide rod bolt(B), After raising the caliper assembly (A), support it with a wire. 3.
Page 906
4. Grease the piston boot to prevent from twisting. 5. Install the guide rod. 6. Install the cylinder assembly (A) to the disc plate. Be careful not to damage the piston boot. 7. Install the guide rod bolt (B). Tightening torque Nm(kgf.m,lb-ft) : 22 ~ 32 (2.2 ~ 3.2, 15.9 ~ 23.1) INSPECTION REAR BRAKE DISC THICKNESS CHECK…
Page 907
REAR BRAKE PAD CHECK 1. Check the pad wear. Measure the pad thickness and replace it, if it is less than the specified value. Pad thickness Standard value : 10.0 mm ( 0.39 in) Service limit : 2.0 mm (0.08 in) 2.
Page 908
3. If the run out does not exceed the limit specification, install the brake disc after turning it 180° and then check the run out of the brake disc again. 4. If the run out cannot be corrected by changing the position of the brake disc, replace the brake disc. Seizing of Rear brake disc 1.
Page 909
Parking Brake System Parking Brake Assembly…
Page 910
2007 > 2.7L V6 GASOLINE > COMPONENTS(1) COMPONENTS(2)
Page 911
COMPONENTS(3)
Page 913
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the lower panel (A), after loosening the parking lever. (Refer to BD group ‘Crash pad’) 2. Remove the parking release nose (B). 3. Remove the parking brake switch (A). [LHD] [RHD] 4.
Page 914
5. Remove the mounting nuts (A) and bolt (B) of the parking brake bracket. [LHD] [RHD] 6. Remove the release cable assembly (C). 7. Remove the damper assembly (A). [LHD]…
Page 915
[RHD] 8. Remove the parking brake lamp switch (A). [LHD] 9. Raise the rear of the vehicle and make sure it is securely supported. 10. Remove the mounting bolt (A) of the parking brake wire bracket from the body.
Page 916
11. Remove the four mounting bolts (A) of the parking brake wire bracket from the rear cross member. 12. Remove the rear wheels and tires from the rear hubs. 13. Remove the hub cap (A) and the disc (B). 14. Remove the hub nut (A) and washer (B) and remove the rear hub (C). 15.
Page 917
16. Remove the adjuster assembly (B) and the lower return spring (C). 17. Remove the strut (B) and the upper return spring (A). 18. Remove the retaining ring (B) of the parking brake wire (A) from back of the backing plate. 19.
Page 918
2. Connect the parking brake wire (B) to the brake shoe (A). 3. Install the shoe hold down pin and spring (A) to hold the brake shoe (B). 4. Install the adjuster assembly (B) and the lower return spring (C). 5.
Page 919
9. Install the hub cap (A) and the disc (B). 10. Install the rear wheels and tires from the rear hubs. 11. Tighten the parking brake adjusting nut. 12. Install the parking brake wire and the pedal assembly. ADJUSTMENT ADJUSTMENT OF REAR BRAKE SHOE CLEARANCE 1.
Page 920
is 200 N(20 kgf, 44 lb) after full stroke operation of parking pedal over 3 times for setting parking wire. a. The parking brake adjustment must be carried out after adjusting the rear shoe. b. After adjusting parking brake, notice following matter; a.
Page 921
Parking Brake Switch…
Page 922
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Remove the floor console and the connector (B) from the switch (A). [LHD] [RHD] 2. Inspect the continuity between (-) terminal and the ground. a. When the brake lever is pulled, there should be the continuity between them. b.
Page 923
( Anti-lock Brake System )
Page 924
2007 > 2.7L V6 GASOLINE > ABS CIRCUIT DIAGRAM(1) ABS CIRCUIT DIAGRAM(2)
Page 925
ECU CONNECTOR INPUT/OUTPUT(ABS) Current max.permissible min.leakage Wire No. Designation wire resistance resistance R_L (mΩ) R_P (kΩ) Ground for recirculation pump 20~39 A 10 A Ground for solenoid valves 5~15 A 2.5 A and ECU Voltage supply for pump 20~39 A 10 A motor Voltage supply for solenoid…
Page 926
Voltage for hybrid ECU 500 mA 200 to signal wheel speed sensor FL, 5,10,17,19 6 mA 16 mA ground 1.5M FR, RL,RR to bat Voltage supply for the active 200 to 16,9,6,8 wheel speed sensor FL,FR, 6 mA 16 mA ground 1.5M RL, RR to bat…
Page 927
FR Wheel speed sensor FR WHEEL Km/h RL Wheel speed sensor RL WHEEL Km/h RR Wheel speed sensor RR WHEEL Km/h ABS Warning lamp ABS LAMP EBD Warning lamp EBD LAMP Brake Lamp B/LAMP Pump relay state PUMP RLY Valve relay state VALVE RLY Motor MOTOR…
Page 928
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.
Page 929
1. ABS WARNING LAMP MODULE The active ABS warning lamp module indicates the selftest and failure status of the ABS.The ABS warning lamp shall be on: a. During the initialization phase after IGN ON. (continuously 3 seconds). b. In the event of inhibition of ABS functions by failure. c.
Page 930
EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel RR : Rear right wheel PE : Pump motor 2. DECREASE MODE Inlet valve(EV) Outlet valve(AV) Pump motor Operation Close Open…
Page 931
EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel RR : Rear right wheel PE : Pump motor 4. INCREASE MODE Inlet valve(EV) Outlet valve(AV) Pump motor Operation Open Close…
Page 932
EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel RR : Rear right wheel PE : Pump motor…
Page 933
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 934
2007 > 2.7L V6 GASOLINE > STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING NOTES WITH REGARD TO DIAGNOSIS The phenomena listed in the following table are not abnormal. Phenomenon Explanation System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment.
Page 935
3. Turn the ignition switch ON. 4. Check for DTC using the Scan tool 5. After completion trouble of the repair or correction of the problem, erase the stored fault codes using the scan tool. 6. Disconnect the Scan tool from the 16P data link connector. ABS CHECK SHEET…
Page 936
PROBLEM SYMPTOMS TABLE Symptom Suspect Area ABS does not operate. Only when 1. -4. are all normal and the problem is still occurring, replace the HECU. a. Check the DTC reconfirming that the normal code is output. b. Power source circuit. c.
Page 937
c. Stop lamp switch circuit. d. Check the hydraulic circuit for leakage. Communication with Scan tool is not possible. a. Power source circuit (Communication with any system is not possible) b. Diagnosis line Communication with Scan tool is not possible. a.
Page 938
control module. Repair if necessary. CHECK THE GROUND CIRCUIT. 1. Disconnect the connector from the ABS control module. 2. Check for continuity between terminals 1,4 of the ABS control module harness side connector and ground point. Is there continuity? ▶ Check the wheel speed sensor circuit. ▶…
Page 939
b. Inoperative wheel speed sensor circuit DTC is displayed, check the following probable cause. When the c. Inoperative hydraulic circuit for leakage problem is still occurring, replace the ABS control module. d. Inoperative HECU INSPECTION PROCEDURES DTC INSPECTION 1. Connect the Scan Tool with the data link connector and turn the ignition switch ON. 2.
Page 940
▶ Replace the leaking hydraulic lines. DETECTING CONDITION Trouble Symptoms Possible Cause Possible malfunction in the power supply system (including ground) a. An open in the wire for the diagnosis line. b. Poor ground c. Inoperative power source circuit INSPECTION PROCEDURES CHECK THE POWER SUPPLY CIRCUIT FOR THE DIAGNOSIS Measure the voltage between terminal 9 of the data link connector and body ground.
Page 941
be probably an open in the HECU power circuit or an open in the b. Inoperative HECU diagnosis output circuit. c. Inoperative power source circuit INSPECTION PROCEDURES CHECK FOR CONTINUITY IN THE DIAGNOSIS LINE 1. Disconnect the connector from the ABS control module. 2.
Page 942
DETECTING CONDITION Trouble Symptoms Possible Cause When current flows in the HECU the ABS warning lamp turns from a. Inoperative ABS warning lamp bulb ON to OFF as the initial check.Therefore if the lamp does not light up, b. Blown No.2 fuse (10A) in the engine the cause may be an open in the lamp power supply circuit, a blown compartment junction block bulb, an open in the both circuits between the ABS warning lamp and…
Page 943
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…
Page 944
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.
Page 945
(6) Wait 60 sec. before operating the air bleeding again. (If not, you may damage the motor.) 5. Pump the brake pedal several times, and then loosen the bleeder screw until fluid starts to run out without bubbles. Then close the bleeder screw. 6.
Page 946
WARNING LAMP DESCRIPTION REMARK О О О C1101 BATTERY VOLTAGE HIGH О О C1102 BATTERY VOLTAGE LOW О О C1200 FL WHEEL SPEED SENSOR- OPEN/SHORT О О C1201 FL WHEEL SENSOR- RANGE/ PERFORMANCE FL WHEEL WHEEL SPEED SENSOR-NO SIGNAL О О…
Page 947
О О О C2332 RR INLET VALVE MALFUNCTION О О О C2336 RR OUTLET VALVE MALFUNCTION О О О C2366 TC VALVE PRIMARY(USV1) ERROR О О О C2370 TC VALVE SECONDARY (USV2) ERROR О О О C2372 ESP VALVE 1(HSV1) ERROR О…
Page 948
ABS Control Unit…
Page 949
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 950
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the air cleaner. (Refer to ‘Master cylinder Removal’) 2. Disconnect the brake tube from the HECU by unlocking the nuts counterclockwise with a spanner. 3. Disconnect the connector(A) from the HECU. 4.
Page 951
Tighterning torque HECU mounting nut : 6~10 Nm (0.6~1.0 kgf·m, 4.34~7.23 Ib-ft) HECU bracket mounting bolt: 17~26 Nm (1.7~2.6 kgf·m, 12.3~18.8 Ib-ft)
Page 952
Front Wheel Speed Sensor…
Page 953
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 954
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the front wheel speed sensor mounting bolt (A) and the wire bracket mounting bolt (B).. 2. Remove the wire bracket bolt (A). 3. Remove the front wheel guard. 4. Remove the front wheel speed sensor after disconnecting the wheel speed sensor connector (A). INSPECTION 1.
Page 955
2. Compare the change of the output voltage of the wheel speed sensor to the normal change of the output voltage as shown below. a. V_low : 0.44 V ~ 0.63 V b. V_high : 0.885 V ~ 1.26 V c.
Page 956
Rear Wheel Speed Sensor…
Page 957
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 958
2007 > 2.7L V6 GASOLINE > REMOVAL 1. Remove the rear wheel speed sensor mounting bolt (A). 2. Remove the rear seat side pad then disconnect the rear wheel speed sensor connector (A). INSPECTION 1. Measure the output voltage between the terminal of the wheel speed sensor and the body ground. In order to protect the wheel speed sensor, when measuring output voltage, a 75Ω…
Page 959
a. V_low : 0.44 V ~ 0.63 V b. V_high : 0.885 V ~ 1.26 V c. Frequency range : 1~2,500 Hz…
Page 960
EBFD (Electronic Brake Force Distribution)
Page 961
2007 > 2.7L V6 GASOLINE > DESCRIPTION The EBD system (Electronic Brake force Distribution) as a sub-system of the ABS system is to control the effective adhesion utilization by the rear wheels. It further utilizes the efficiency of highly developed ABS equipment by controlling the slip of the rear wheels in the partial braking range.
Page 962
(Electronic Stability Program) System…
Page 963
2007 > 2.7L V6 GASOLINE > ESP circuit DIAGRAM(1) ESP circuit DIAGRAM(2)
Page 964
ESP circuit DIAGRAM(3)
Page 965
ESP HECU CONNECTOR INPUT / OUTPUT Connector Terminal Specifications Conditions Description Current range : Min-10 A Ground(Pump) Always Max-20 ~ 39 A Current range : Min-2.5 A Ground(Valve,ECU) Always Max-5 ~ 15 A Supply voltage(Pump) Battery voltage Always Supply voltage(Valve)
Page 966
Wheel sensor voltage(FL) Wheel sensor voltage(FR) Battery voltage IG ON Wheel sensor voltage(RL) Wheel sensor voltage(RR) Wheel sensor signal(FL) Wheel sensor signal(FR) Voltage(High) : 0.89~1.26 V RUNNING Voltage(Low) : 0.44~0.63 V Wheel sensor signal(RL) Wheel sensor signal(RR) Voltage(High) : 0.8 * IG ON more SCAN TOOL Diagnosis Input/oupput Voltage(Low) : 0.2 * IG ON lower…
Page 967
2007 > 2.7L V6 GASOLINE > description of ESP Optimum driving safety now has a name : ESP, the Electronic Stability Control. ESP recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention with no needfor actuating the brake or the gas pedal. ESP adds a further function known as Active Yaw Control (AYC) to the ABS, TCS, EBD and ESP functions.
Page 968
VARIANT CODING The HECU is programmed with a variant code based on the vehicle powertrain configuration. This variant code is used to determine the appropriate ESP calculations. Variant code programming should be performed whenever an HECU is replaced. PROCEDURE OF VARIANT CODING 1.
Page 969
5. Select the variant coding. 6. Follow the next procedure according to the comment . 7. Confirm the condition , and then push the «REST». 8. If the procedure is finished, the screen is displayed as shown below. 9. IGN off. 10.
Page 970
If the warning lamp(ESP, EBD, ABS) is illuminated, follow the «Variant coding» again. INPUT AND OUTPUT DIAGRAM ESP OPERATION MODE 1. STEP 1 The ESP analyzes the intention of the driver.
Page 971
2. STEP 2 It analyzes the movement of the ESP vehicle. 3. STEP 3 he HECU calculates the required strategy, then actuates the appropriate valves and sents torque control requests via CAN to maintain vehicle stability. ESP OPERATION MODE 1. ESP Non-operation-Normal braking. High pressure Inlet valve(EV) Outlet valve(AV)
Page 972
USV : Pilot Valve HSV : High pressure Switch Valve 2. ESP INCREASE MODE High pressure Inlet valve(EV) Outlet valve(AV) Pilot valve(USV) Pump motor switch valve(HSV) ON(Motor speed Normal braking Open Close Close(Partial) Open control) EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel…
Page 973
EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel RR : Rear right wheel PE : Pump motor USV : Pilot Valve HSV : High pressure Switch Valve 4.
Page 974
EV : Inlet Valve AV : Outlet Valve LR : Rear left wheel RF : Front right wheel LF : Front left wheel RR : Rear right wheel PE : Pump motor USV : Pilot Valve HSV : High pressure Switch Valve ABS Warning Lamp module The active ABS warning lamp module indicates the self-test and failure status of the ABS .The ABS warning lamp shall be on:…
Page 975
The active EBD warning lamp module indicates the self-test and failure status of the EBD. However, in case the Parking Brake Switch is turned on, the EBD warning lamp is always turned on regardless of EBD functions. The EBD warning lamp shall be on: a.
Page 976
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 977
2007 > 2.7L V6 GASOLINE > FAILURE DIAGNOSIS 1. In principle, ESP and TCS controls are prohibited in case of ABS failure. 2. When ESP or TCS fails, only the failed system control is prohibited. 3. However, when the solenoid valve relay should be turned off in case of ESP failure, refer to the ABS fail-safe. 4.
Page 978
Steering Angle Sensor…
Page 979
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The yaw-rate & lateral G sensor is applied for the ESP system. 2. The yaw-rate is the angular velocity, when a vehicle turns a corner, and the lateral G is the acceleration to move a vehicle out of the way when cornering.
Page 980
CIRCUIT DIAGRAM (YAW-RATE & LATERAL G SENSOR)
Page 981
ESP OFF Switch…
Page 982
2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. The ESP OFF switch is for the user to turn off the ESP system. 2. The ESP OFF lamp is on when ESP OFF switch is engaged.
Page 983
Yaw — rate Lateral G Sensor…
Page 984
2007 > 2.7L V6 GASOLINE > INSPECTION 1. Remove the ESP OFF switch from the switch panel on the crach pad of the driver’s side. 2. Check the continuity between the switch terminals as the ESP OFF switch is engaged.
Page 985
Steering Angle Sensor…
Page 986
2007 > 2.7L V6 GASOLINE > DESCRIPTION GENERAL DATA The steering angle speed sensor detects the angle of the steering wheel in order to which direction a user chooses. MEASUREING PRINCIPLE A non contact, analog angle sensor carrying out absolute measuring by the use of the Anisotropic-Magneto-Resistive effect (AMR).Measuring of the absolute angle by means of a toothed measuring gear with magnetic properties in combination with different ratios.
Page 987
c. A steering angle sensor used in ESP adjusts 0° setting of steering wheel through K-line or CAN communication. 2. STEERING ANGLE SENSOR (SAS) CALIBRATION METHOD (1) Align the wheel to the straight line. (steering wheel < ± 5° ) ex) Perform the wheel alignment first.
Page 988
(7) The procedure is finished. Push the «ESC» key. (8) Scanner OFF. (9) Remove the scanner from the vehicle. (10) Confirm the Steering angle sensor(SAS) calibration as driving the vehicle.(turn left once, turn right once)
Page 989
CHAPTER 14: Body (Interior and Exterior)
Page 990
General information…
Page 991
2007 > 2.7L V6 GASOLINE > SPECIAL TOOLS Tool (Number and name) Illustration 09793-21000 Adjustment, removal and installation Door hinge adjusting wrench Of the door hinge 09800-21000 Trim removal Ornament remover 09853-31000 Removal of the headliner clips Headliner clip remover 09861-31100 Cutting the sealant of the windshield Sealant cut-out tool…
Page 992
09880-4F000 Installation of the hogring clip Hogring clip installer…
Page 993
2007 > 2.7L V6 GASOLINE > TROUBLESHOOTING Symptom Suspect Area Remedy (See page) Water leaks from sunroof Dirt accumulated in drain tube Clear dirt inside of drain Clogged drain tube Blow air into drain to remove dirt Broken or dislocated drain tube, defective Check tube installation and Or cracked clip Flange contact…
Page 994
2007 > 2.7L V6 GASOLINE > SPECIFICATIONS HOOD Type Rear hinged, gas lifter type Construction Front hinged, full door construction REAR DOOR Regulator system X-ARM type Locking system Pin-fork system Construction Sliding door construction FRONT DOOR Regulator system Wire drum type Locking system Pin-fork system TAILGATE…
Page 995
Exterior…
Page 996
Fender…
Page 997
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.
Page 998
Hood…
Page 999
2007 > 2.7L V6 GASOLINE > REPLACEMENT HOOD ASSEMBLY REPLACEMENT a. When removing and installing the hood, an assistant is necessary. b. Take care not to damage the hood and body. c. When removing the clips, use a clip remover. 1.
Page 1000
HOOD INSULATOR REPLACEMENT 1. Using a clip remover, detach the clips, and remove the hood insulator (A). a. Take care not to scratch the hood panel.
Page 1001
2. Installation is the reverse of removal. a. Replace any damaged clips. HOOD WEATHERSTRIP REPLACEMENT 1. Detach the clips, then remove the hood weatherstrip(A). Take care not to scratch the hood. 2. Installation is the reverse of removal. a. Replace any damaged clips. HOOD SEAL WEATHERSTRIP REPLACEMENT 1.
Page 1002
2. Installation is the reverse of removal. a. Replace any damaged clips. HOOD LIFT REPLACEMENT 1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifter (D), and then remove the lifter from the bracket (C). 2.
Page 1003
2. Installation is the reverse of removal. a. Make sure the hood latch cable is connected properly. b. Make sure the hood locks securely. HOOD LATCH REPLACEMENT 1. Detach the clips, then remove the under cover(A). 2. Detach the clips, then remove the hood latch cover(A).
Page 1004
3. Remove the hood latch (A) mounting bolts. 4. Remove the latch (A). 5. Disconnect the hood latch cable (A) and Remove the latch (B). 6. Installation is the reverse of removal. a. Make sure the hood latch cable is connected properly. b.
Page 1005
1. Remove the wiper (A). 2. Remove the hood seal weather strip. 3. Detach the clips, then remove the cowl top cover (A). 4. Installation is the reverse of removal. HOOD ADJUSTMENT PROCEDURES 1. After loosening the hinge (A) mounting bolt, adjust the hood (B) by moving it up or down, or right or left. 2.
Page 1007
Taligate…
Page 1008
2007 > 2.7L V6 GASOLINE > REPLACEMENT INSIDE HANDLE REPLACEMENT 1. After loosening the mounting screws, remove the inside handle (A). 2. Installation is the reverse of removal. ROOM LAMP REPLACEMENT 1. Remove the room ramp. a. Remove the lens (A). b.
Page 1009
b. Inside handle 2. Disconnect the clip (A), remove the tailgate lifter (B). 3. Using a screwdriver, remove the tailgate switch (A). 4. Disconnect the connector (B). 5. Using a screwdriver, remove the tailgate upper trim (A). 6. Loosen the screw, then remove tailgate side trim (A).
Page 1010
7. Loosen the screws and clips to the lower tailgate trim (A). 8. Installation is the reverse of removal. a. Replace and damaged clips. TAILGATE WEATHERSTRIP REPLACEMENT 1. Remove the tailgate weather strip (A).
Page 1011
2. Installation is the reverse of removal. LATCH ASSEMBLY REPLACEMENT 1. Remove the tailgate trim. 2. Disconnect the outside handle rod (A), connector (B). 3. After loosening the mounting screws, then remove the latch assembly (A). 4. Installation is the reverse of removal. a.
Page 1012
4. Installation is the reverse of removal. a. Make sure the connector is connected properly and the connecting rod is connected properly. b. Make sure the tailgate opens properly and locks securely. OUTSIDE HANDLE REPLACEMENT 1. Remove the tailgate trim. 2.
Page 1013
5. Installation is the reverse of removal. a. Make sure the tailgate opens properly and locks securely. LIFTER REPLACEMENT 1. Using a screwdriver (A), lift up slightly the socket clips (B) of both ends on the lifter (D), and then remove the lifter from the bracket (C).
Page 1014
2. Push the socket of the lifter into the bracket for installation. KEY HOLDER REPLACEMENT 1. Remove the tailgate trim. 2. Remove the tailgate garnish. 3. Disconnect the key rod (B) and connector (A). 4. Remove the key holder (A).
Page 1015
5. Installation is the reverse of removal. a. Make sure the tailgate opens properly and locks securely. POWER TAILGATE MOTER ASSEMBLY REPLACEMENT 1. Remove the rear seat assembly. 2. Remove the luggage trim. 3. Disconnect the clip (A), remove the tailgate lifter (B). 4.
Page 1016
a. Make sure the connector is plugged in properly. b. Make sure the tailgate opens properly and locks securely. REAR WIPER REPLACEMENT 1. Using a screwdriver, detach cover (A). 2. Remover the rear wiper (A). 3. Installation is the reverse of removal. REAR WIPER MOTER ASSEMBLY REPLACEMENT 1.
Page 1017
3. Remove cover (A). 4. Loosen the mounting nut (A). 5. After disconnecting the connector (A), remove the motor (B). 6. Installation is the reverse of removal. a. Make sure the connector is plugged in properly. b. Make sure the rear wiper. FUEL FILL DOOR REPLACEMENT 1.
Page 1018
2. Loosen the bolts, then remove the fuel fill door (A). 3. Remove the fuel fill door (B). 4. Installation is the reverse of removal. a. Make sure the fuel fill door opens properly and locks securely. 5. Check that the fuel fill door (A) fits flush against the body. If necessary, adjust it.
Page 1019
TAILGATE ADJUSTMENT PROCEDURES 1. After loosening the tailgate hinge (A) mounting bolt, adjust the tailgate by moving it up or down, or right or left. 2. Adjust the tailgate fit by closing the tailgate over slam bumper and side bumper (B). 3.
Page 1021
Front Door…
Page 1022
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 1023
2007 > 2.7L V6 GASOLINE > REPLACEMENT FRONT DOOR TRIM REPLACEMENT a. Take care not to scratch the door trim and other parts. b. Put on gloves to protect your hands. 1. Remove the quadrant inner cover (A). 2. Loosen the mounting screw, remove the inside handle cover (A). 3.
Page 1024
[RHD] 4. Installation is the reverse of removal. a. Make sure of connectors is plugged in properly and each rod is connected securely. b. Make sure the door locks and opens properly. GLASS REPLACEMENT 1. Remove the front door trim. 2.
Page 1025
a. Roll the glass up down to see if it moves freely without binding. b. Make sure that there is no clearance between the glass and glass run channel when the glass is closed. c. Adjust the position of the glass as necessary. INSIDE HANDLE REPLACEMENT 1.
Page 1026
3. Installation is the reverse of removal. POWER WINDOW MOTOR REPLACEMENT 1. Remove the door trim . 2. Disconnect the power window motor connector (A). 3. After loosening the mounting nuts, remove the power window motor (B). 4. Installation is the reverse of removal. a.
Page 1027
3. Installation is the reverse the removal. a. Make sure the door locks and opens properly. DOOR MODULE ASSEMBLY REPLACEMENT 1. Remove the following parts. a. Front door trim. b. Glass. c. Channel. 2. Disconnect the wiring harness (A). 3. Disconnect the lock rod (A) and outside handle rod (B). 4.
Page 1028
5. Installation is the reverse of removal. a. Make sure the connector is plugged in properly and each rod is connected securely. b. Make sure the door locks and opens properly. OUTSIDE HANDLE REPLACEMENT 1. Remove the door trim. 2. Remove the door trim seal. 3.
Page 1029
6. After removing the outside handle mounting bolts, remove the outside handle (A). 7. Installation is the reverse the removal. a. Make sure the door locks and opens properly. DOOR BELT WEATHERSTRIP REPLACEMENT 1. Loosen the mounting screw, then remove the door belt weather strip (A). 2.
Page 1030
2. Remove the glass. 3. Loosen the rear channel mounting nuts. 4. After disconnecting the glass molding, remove the rear channel (A). 5. Installation is the reverse of removal. DOOR WEATHERSTRIP REPLACEMENT 1. Loosen the checker mounting bolts. 2. Release the clips then remove the door weatherstrip(A). 3.
Page 1031
5. Installation is the reverse the removal. ADJUSTMENT GLASS ADJUSTMENT a. Check the glass run channel for damage or deterioration, and replace them necessary. 1. Remove the following parts. a. Quadrant cover. b. Door trim. 2. Carefully move the glass until you can see the glass mounting bolts, then loosen them. 3.
Page 1032
b. Loosen the hinge mounting bolts (C) slightly, and move the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps. c. Place a shop towel (D) on the jack (E) to prevent damage to the door when adjusting the door. 3.
Page 1033
2. Lightly tighten the screws. 3. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer. Do not tap the striker too hard. 4. Loosen the screws and remove the shop towel. 5.
Page 1034
Rear Door…
Page 1035
2007 > 2.7L V6 GASOLINE > COMPONENTS…
Page 1036
2007 > 2.7L V6 GASOLINE > REPLACEMENT REAR DOOR TRIM REPLACEMENT a. Take care not to scratch the door trim and other parts. b. Put on gloves to protect your hands. 1. Remove the front side trim(A) and rear side trim. 2.
Page 1037
5. Installation is the reverse of removal. GLASS REPLACEMENT 1. Remove the following items. a. Door trim. b. Door belt weather strip. c. Rear channel. a. Take care not to drop to glass and scratch the glass surface. 2. Carefully move the glass (A) until you can see the bolts, then loosen them. Separate the glass run from the door panel and carefully pull the glass out through the window slot.

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Manufacturer: KIA, Model Year: 2007,
Model line: CARNIVAL,
Model: KIA CARNIVAL 2007
Pages: 1575, PDF Size: 44.86 MB

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File Specifications:

2244/2244774-carnival_2007.pdf file (13 Mar 2023)

Accompanying Data:

Kia Carnival 2007 Automobile PDF Workshop Manual (Updated: Monday 13th of March 2023 05:19:07 AM)

Rating: 4.9 (rated by 6 users)

Compatible devices: Carens 2014, 2014 Sportage, 2004.5 Spectra, Optima 2004, Soul EX, Sorento 2005, Sportage 2013, 2020 Telluride.

Workshop Manual (Text Version):

(Ocr-Read Summary of Contents of some pages of the Kia Carnival 2007 Document (Main Content), UPD: 13 March 2023)

1260, 4. Operation control a. Prioritization of operations Motor starting is delayed for 100ms respectively in case of auto control to prevent rush current from overlap when motors are running, and it follows the following order. Slide > recline > front height > rear height > adjust pedal b. Memory preset recall is conducted in the following order, and delay time for each motor is as follows. T1 : Manimum 0.1 sec. Continuous co…
914, 5. Remove the mounting nuts (A) and bolt (B) of the parking brake bracket. [LHD] [RHD] 6. Remove the release cable assembly (C). 7. Remove the damper assembly (A). [LHD]
…
1323, Kia Carnival 2007 2007 > 2.7L V6 GASOLINE > DESCRIPTION Power Sliding Door is an electro-mechanical system designed to provide power opening and closing of a vehicle’s sliding door through the push of a button of the transmitter key or the main control buttons on the overhead console or the sub control buttons on the center pillar trim or inside/outside door handle switch. The power sliding door will reverse direction of travel if resistance to movement is detected while the door is being cl…
324, INSTALLATION 1. Install the Fuel Pump assembly according to the reverse order of «REMOVAL» procedure. Fuel Pump assembly mounting bolts : 2.0 ~ 2.9 N·m (0.2 ~ 0.3 kgf·m, 1.4 ~ 2.2 lbf·ft)
…
1290, 2007 > 2.7L V6 GASOLINE > INSPECTION FUSE 1. Be sure there is no play in the fuse holders, and that the fuses are held securely. 2. Are the fuse capacities for each circuit correct? 3. Are there any blown fuses? If a fuse is to be replaced, be sure to use a new fuse of the same capacity. Always determine why the fuse blew first and completely eliminate the problem before installing a new fuse. RELAY 1. Be sure that the relays are held the each mod…
1518, Kia Carnival 2007 the old one. There are no transponder-related data stored in this device. 1. Things to remember before replacing (PCM(ECM)) 2. Things to remember before a replacement (Keys & Additional registration) a. When there is only one key registered and you wish to register another key, you need to re-register the key which was already registered. b. When the key #1 is registered and master key #2 is not registered, Put the key #1 in the …
1352, 3. Select power sliding door. 4. Select the sensor output. And then check the anti pinch strip sensor output while operating power sliding door in power mode. ※ Above voltage and numerical value may be different from the real value. 5. Change the anti pinch strip sensor, if there is no change from OFF to ON during operation.
…
438, 19. Install the under cover(A). 20. Install the steering column joint bolt.(See ST group). 21. Install the front wheels and tires. (see SS group) 22. Install the transaxle insulator and mounting bracket (B) by tightening the bolts (A). TORQUE: 60~80 Nm (6~8 kgf.m, 43.6~58.2 lb-ft) 23. remove the SST (09200-38001) holding the engine and transaxle assembly. TORQUE: 65~85 Nm (6.5~8.5kgf.m, 47.0~61.5 lb-ft)
…
84, (6) If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. (7) If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the …
400, 2007 > 2.7L V6 GASOLINE > INSPECTION 1. If the value is out of specification according to the chart below, remove the valve body cover. 2. Measure the resistance again after disconnecting solenoid valve connector. Specification (20°C): 4.3 ~ 4.4Ω (VFS) 3. If the value is out of specification replace the solenoid valve. Pin No. Name Resistance 7&8 VFS 4.3~4.4Ω (20°C)
…
1213, Head Lamps Low Beam Function 1. Necessary conditions to switch ON : a. By putting the Head lamp switch in position ‘Head lamp Low Beam’ or Auto light activation or DRL activation. 2. Necessary conditions to switch OFF : a. If they are released by the Head lamp switch (Auto light function deactivated) and if the DRL function is deactivated b. If the Auto light function is active but the Auto light sensor signal status is not ‘HL ON’. 3. Functional diagra…
718, 2007 > 2.7L V6 GASOLINE > DESCRIPTION 1. Heater unit includes mode control actuator and temperature control actuator. 2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then temperature will be regulated by the hot/cold ai…
162, 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 …

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