The Kia Carnival is a minivan manufactured by Kia Motors, introduced
in September 1998, marketed globally under various nameplates �
prominently as the Kia Sedona � and currently in its second
generation.First generation models stay in production (e.g., in China).
Second generation models have been marketed since model year 2006 �
including as a rebadged variant in the United States, the Hyundai
Entourage for model years 2007�2009.The Kia Sedona first generation was
marketed globally, for example as the Naza Ria in Malaysia. The first
generation model is currently marketed and manufactured in particular
regions, including under a joint venture in the Chinese market with
Dongfeng Yueda Kia Automobile Company.In the United States, the very
first generation Sedona competed with the minivan segment of Toyota
Sienna, Honda Odyssey, Ford Windstar/Ford Freestar and the Chrysler
minivans � and was Kia's top-selling vehicle when it launched.With a 3.5
L V6 engine making 195 hp (145 kW) and a 4-speed automatic (later a
5-speed automated transmission), the Sedona lacked features that other
minivans had these types of as power sliding doors and power liftgate, a
fold flat 3rd row seat, navigation system, rear-view camera, and backup
sensors. Early Sedonas had been rated at 15.6 L/100 km (15.1 mpg)
(city) and 10.9 L/100 kilometer (21.6 mpg) (highway), but the numbers
improved slightly to 14.8 L/100 km (15.9 mpg) (city) and 9.6 L/100 km
(24.5 mpg) (highway) for 2005 models.
In Australia, the Kia Carnival went on sale in 1999,
with a standard 5-speed manual and 2.5 L V6 producing 177 hp (132 kW). A
4-speed automatic was optional. In 2001, it outsold the Toyota Tarago,
becoming the top-selling minivan in the nation. It was sales frontrunner
again in 2004 and 2005, when sales peaked at 5,259 units, which in
itself was a record for any minivan.In European countries is available
only with the 2.5 Rover KV6 engine 24V petrol with 163 PS and Euro 2
standard emission levean as well as the 2,9 litres turbodiesel engine
with 126 PS. From 2001 Kia Motors introduce the 2.5 KV6 Euro 3 with 150
PS and the new 2.9 CRDI common rail diesel engine with 144 PS.Shown left
is the 2005 Kia Sedona EX (US), the EX is the highest body style with
all the amenities such as interior and exterior chrome accents, interior
wood grain, leather wrapped steering wheel and gear shift knob and
alloy tires, with optional fabric appointed seating, sunroof, DVD player
and much more.In the 2007 reliability report published by 1st
generation (1999�2005) of Kia Carnival put 113th out of 113 in the 2 to
3-year-old cars category, with a defect rate of 25.1%. In the 2008
T report, 1st generation (1999�2005) of Kia Carnival placed 116th
out of 116 in the same category, with a defect price of 19.70%, and also
placed 111th out of 111 in the 4 to 5-year-old cars category, with a
defect rate of 27.60%.
According to MSN autos dependability study, 2006 Kia Sedona reliability
rated as overall, good 5/5. It rated as "Minimal Problems", and comment
as "Infrequent problems reported, all with low repair costs." MSN Autos
use Identifix for data on all automobiles.According to MyRide.com
reliability survey, The MyRide Reliability reviews are collected from
visitors and previous customers of Autobytel Inc.'s websites
(CarSmart.com, Autobytel.com and Autoweb.com) who have cars from model
year 2001 and newer via an online survey conducted by an independent
third party.The 2009 Kia Sedona's JD Power reliability score is same as
the 2009 Honda Odyssey and 2009 Dodge Grand Caravan.
Kia Carnival / Sedona factory workshop and repair manual 1999-2006 2000 2001 2002 2003 2004 2005 Download
### CV Joint Replacement on Kia Carnival/Sedona: Step-by-Step Guide
#### Tools Needed
1. **Jack and Jack Stands** - To lift and secure the vehicle.
2. **Lug Wrench** - To remove wheel nuts.
3. **Socket Set** - 10mm, 12mm, 14mm, 17mm, and 19mm sockets.
4. **Ratchet and Extensions** - For easier access to bolts.
5. **Pry Bar** - To help remove the axle.
6. **Hammer** - For tapping out the CV joint.
7. **Torque Wrench** - To ensure proper bolt torque.
8. **CV Joint Puller Tool** - Optional, but helpful for removing the joint.
9. **Grease** - For new CV joint.
10. **Safety Glasses** - Eye protection.
11. **Gloves** - To protect hands.
12. **Drain Pan** - To catch any spilled fluid.
13. **Shop Manual** - For torque specifications and detailed instructions.
#### Safety Precautions
- Always work on a flat, stable surface.
- Use jack stands after lifting the vehicle with a jack; never rely solely on a hydraulic jack.
- Ensure the vehicle is in gear or use wheel chocks on the opposite end.
- Wear safety glasses and gloves to protect against debris and sharp objects.
#### Step-by-Step Instructions
1. **Preparation**
- Park the vehicle on a level surface, engage the parking brake, and wear safety gear.
2. **Lift the Vehicle**
- Loosen the lug nuts slightly while the vehicle is on the ground.
- Use a jack to lift the vehicle and secure it with jack stands.
- Remove the wheel completely.
3. **Remove the Axle Nut**
- Use a socket and ratchet to remove the axle nut (typically 30mm).
- If the nut is stuck, use a breaker bar for additional leverage.
4. **Detach the Lower Control Arm (if necessary)**
- Locate and remove the bolts attaching the lower control arm to the knuckle.
- Use a pry bar to gently separate the control arm from the knuckle.
5. **Remove the CV Joint**
- Gently tap the CV joint with a hammer or use a CV joint puller to pop it out of the transmission.
- Be cautious not to damage the transmission seal.
6. **Install the New CV Joint**
- Apply grease to the new CV joint as per manufacturer specifications.
- Align and insert the new CV joint into the transmission. Ensure it is seated properly.
7. **Reattach the Control Arm**
- Position the lower control arm back into the knuckle and tighten the bolts to manufacturer specifications.
- Use a torque wrench for accurate tightening.
8. **Reinstall the Axle Nut**
- Place the axle nut back on and tighten it to the specified torque (typically around 150-200 lb-ft).
- Ensure the nut is properly seated to avoid future issues.
9. **Reinstall the Wheel**
- Place the wheel back onto the hub, hand-tighten the lug nuts, and lower the vehicle.
- Once on the ground, use a torque wrench to tighten the lug nuts to the specified torque.
10. **Final Checks**
- Inspect the CV joint for any leaks or improper installation.
- Check the lower control arm and axle nut for tightness.
- Take the vehicle for a short test drive to ensure everything is functioning correctly.
#### Common Pitfalls to Avoid
- **Forgetting to Secure the Vehicle**: Always use jack stands. Never work under a vehicle only supported by a jack.
- **Not Using Proper Torque Specs**: Always use a torque wrench to prevent over-tightening or under-tightening bolts.
- **Damage to the Transmission Seal**: Be gentle when removing the CV joint to avoid damaging the seal.
- **Incorrect Installation of the New Joint**: Ensure the new CV joint clicks into place properly before reassembling.
#### Replacement Parts
- Always use OEM or high-quality aftermarket parts for the CV joint.
- Consider replacing the CV boot if it is damaged, as it is crucial for preventing dirt and debris from entering the joint.
By following these steps and precautions, you should be able to successfully replace the CV joint on a Kia Carnival/Sedona.
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Replacing the clutch plate on a Kia Carnival/Sedona involves several key steps that address the wear and failure of the clutch system. Here’s a theoretical breakdown of the process and how it resolves the issue:
### Theory of Clutch Functionality
1. **Clutch Basics**: The clutch connects and disconnects the engine from the transmission. It allows the driver to change gears without stalling the engine. The clutch plate, part of the clutch assembly, is the component that engages and disengages the engine's power to the transmission.
2. **Symptoms of Wear**: Symptoms of a failing clutch plate include slipping (engine revs without corresponding vehicle acceleration), difficulty in shifting gears, or unusual noises. These symptoms indicate that the friction material on the clutch plate is worn down, reducing its ability to grip.
### Replacement Process
1. **Preparation**:
- **Safety**: Disconnect the battery to prevent electrical issues and ensure safety.
- **Fluid Drainage**: Drain the transmission fluid to prevent spillage during disassembly.
2. **Access the Clutch**:
- **Remove Components**: To access the clutch assembly, remove the transmission from the engine. This typically involves removing the driveshaft (if applicable), disconnecting the transmission mounts, and unbolting the transmission from the engine.
- **Separation**: Carefully separate the transmission from the engine, which exposes the clutch assembly.
3. **Inspect and Remove the Old Clutch Plate**:
- **Inspection**: Check the old clutch plate for wear, cracks, or glazing. This indicates failure points.
- **Removal**: Unbolt the pressure plate and remove the old clutch plate. The pressure plate springs apply force to the clutch plate, ensuring it engages the flywheel. If the pressure plate is also worn, it may need replacement.
4. **Install the New Clutch Plate**:
- **Alignment**: Position the new clutch plate and align it using a clutch alignment tool. Proper alignment is crucial for smooth engagement.
- **Pressure Plate Installation**: Reattach the pressure plate, ensuring it applies even pressure across the clutch plate. This restores proper engagement and disengagement capabilities.
5. **Reassemble the Transmission**:
- **Reattach Transmission**: Carefully align and bolt the transmission back to the engine. Ensure all mounts and connections are secure.
- **Fluid Refill**: Refill the transmission with the appropriate fluid to ensure lubrication.
6. **Testing**:
- **Function Test**: Reconnect the battery and start the vehicle. Test the clutch operation by engaging and disengaging gears, checking for smooth operation without slipping or unusual noises.
### Resolution of Fault
By replacing the worn clutch plate, you restore the necessary friction surface that allows for effective power transfer from the engine to the transmission. This fixes symptoms such as slipping and difficulty in shifting, ultimately restoring the vehicle's drivability and performance. Proper installation ensures that the clutch operates correctly, prolonging the life of the entire clutch system and enhancing vehicle reliability.
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- **Safety Gear**
- **Safety Glasses**: Protect your eyes from debris and chemicals.
- **Gloves**: Protect your hands from sharp edges and hot components.
- **Ear Protection**: If using power tools, protect your hearing.
- **Basic Tools Needed**
- **Jack and Jack Stands**:
- **Usage**: To lift the vehicle safely for access to the exhaust system.
- **Importance**: Allows you to work underneath the vehicle without risk of it falling.
- **Wrench Set (Metric)**:
- **Usage**: To remove bolts and nuts from the exhaust components.
- **Importance**: Different sizes are needed for various bolts; typically, 10mm, 12mm, and 14mm are common for exhaust systems.
- **Socket Set**:
- **Usage**: Provides a faster way to remove bolts than a wrench.
- **Importance**: Ratchet allows for quick tightening and loosening; usually, a 3/8” drive socket set will suffice.
- **Pliers**:
- **Usage**: To grip and manipulate various components, especially clamps.
- **Importance**: Useful for removing or tightening exhaust clamps that may be rusted.
- **Torque Wrench**:
- **Usage**: To ensure bolts are tightened to the manufacturer’s specifications.
- **Importance**: Prevents over-tightening or under-tightening, which can cause leaks or damage.
- **Cutting Tool (Hacksaw or Exhaust Pipe Cutter)**:
- **Usage**: If a section of the exhaust needs to be cut out.
- **Importance**: Allows for precise cutting of old or damaged pipes.
- **Replacement Parts**:
- **Exhaust Gasket**:
- **Why Replace**: Often deteriorates over time, leading to leaks.
- **Replacement Part**: A specific gasket for your Kia Carnival/Sedona model.
- **Exhaust Pipe or Muffler**:
- **Why Replace**: If it is rusted, cracked, or damaged, it can cause noise and performance issues.
- **Replacement Part**: OEM or aftermarket parts designed for Kia Carnival/Sedona.
- **Exhaust Hangers**:
- **Why Replace**: May break or wear out, leading to vibrations and misalignment.
- **Replacement Part**: Specific hangers for your vehicle.
- **Procedure Overview**
- **Lift Vehicle**:
- Use the jack to lift the vehicle and securely place jack stands under safe points.
- **Inspect Exhaust System**:
- Look for rust, holes, or broken components. Identify what needs replacing.
- **Remove Old Exhaust Components**:
- Use the wrench or socket set to remove bolts and disconnect any hangers.
- If needed, use cutting tools to remove damaged sections.
- **Install New Components**:
- Fit new parts in place, ensuring gaskets are installed where needed.
- Use a torque wrench to tighten bolts to the manufacturer’s specifications.
- **Recheck Installation**:
- Ensure all connections are secure and there are no gaps.
- **Lower Vehicle**:
- Carefully remove jack stands and lower the vehicle.
- **Test Drive**:
- Start the engine and listen for any unusual noises. Check for leaks under the vehicle.
- **Post-Repair Inspection**
- **Visual Check**: Inspect for any visible gaps or loose connections.
- **Sound Check**: Listen for any hissing or loud noises indicating a leak.
- **Performance Check**: Ensure the vehicle runs smoothly without any performance issues.
This guide provides a beginner-friendly approach to exhaust repair on a Kia Carnival/Sedona, ensuring you understand the tools required and the necessity for replacement parts.
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