Kia Carnival (2007 year). Manual — part 463

2007 > J2.9L DIESEL CRDI(VGT) >

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 the brake fluid fron the clutch master cylinder reservoir with a syringe.

2. Clamp the clutch master cylinder hose(A). If there is no enough room for clamping, you can also clamp the hose

from the brake master cylinder side.

3. Disconnect the hose(A) from the cylinder by releasing the clutch master cylinder clamp.

4. Remove the clutch master cylinder mounting bolts(A,B).

One is the engine room, the other near the clutch pedal assembly.

5. Remove the pin and washer which connect the clutch pedal with the clutch master cylinder.

6. Remove the clutch master cylinder. It can be helpful to do this step after removing the clutch pedal mounting

bracket.

INSTALLATION

Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.

CONCENTRIC SLAVE CYLINDER AIR BLEEDING PROCEDURE

1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.

2. Loosening the plug screw, press and release the clutch pedal about 10 times.

Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or
tightened.

3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.

TORQUE :
25~29Nm (250~290Kgf.cm, 18.2~21.1lb-ft)

4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it

again, then.

5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

a. Do not clamp the pipe of a concentric slave cylinder.
b. Be careful not to damage O-rings.

Clutch Pedal

2007 > J2.9L DIESEL CRDI(VGT) >

ADJUSTMENT PROCEDURE

IGNITION LOCK SWITCH

1. Disconnect 2P-connector from a ignition lock switch.

2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)

3. Check for continuity between terminals. (refer to the table below)

Clutch pedal position

Ignition lock switch

Continuity

Released

Released

NO

Pressed

Pressed

YES

If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
If not, install the ignition lock switch and adjust the clutch pedal.

TORQUE :
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)

Clutch pedal and Ignition lock switch

a. Inspect a ignition lock switch.
b. Remove the driver's seat mat to adjust a clutch pedal.
c. No gap between a clutch master cylinder pistion and push rod can cause clutch slip.

1. Loosen and draw out the bolt until it is off the pedal surface.

2. Push and pull a clutch master cylinder push rod to satisfy the specification below.

Specification:
Clutch pedal stroke(A) - 150mm(5.91in)
Clutch pedal free play(B) - 6~13mm(0.24~0.51in)
Clutch pedal distance - 234.7mm(9.24in)

3. With no pressure on a clutch pedal, tighten the bolt until it contacts on the pedal.

4. Fix the bolt with a nut.

TORQUE :
14~20Nm (140~200kgf.cm, 10.2~14.5lb-ft)