Kia Carnival / Sedona factory workshop and repair manual download

Tools & supplies
- Basic hand tools: ratchet, 3/8" & 1/2" drive socket set (including 8, 10, 12, 13 mm depending on year), extensions, combination wrenches
- Torque wrench (ft‑lb and/or Nm)
- Serpentine/belt tensioner tool or long breaker bar (for tensioner)
- Pulley puller (3‑jaw or 2‑arm, small automotive type) OR strap wrench/impact if removing center bolt only
- Pry bar or large screwdriver (careful)
- Penetrating oil (PB Blaster)
- Drain pan, coolant (specified type), funnel
- New water pump pulley (part number for your model/year) and replacement bolts if specified
- Replacement serpentine belt (inspect and replace if >5 years or cracked)
- Thread locker (medium strength) if manufacturer calls for it
- Jack, jack stands or ramps, wheel chocks
- Gloves, safety glasses, shop rags

Safety precautions
- Work on a cold engine. Never open the cooling system when hot.
- Park on level ground, set park, chock rear wheels.
- Disconnect negative battery terminal.
- Support vehicle with jack stands if you need to raise it; never rely on a jack alone.
- Wear eye protection and gloves. Catch coolant in a pan and dispose of it properly.

Quick notes before starting
- Always verify the exact procedure & torque values for your model/year in the factory service manual. Pulley hardware size and torque vary by engine.
- Many Kia water‑pump pulleys are bolted to the pump shaft and can be replaced separately; on some engines the pulley and pump may be integral — inspect first.
- If the pulley bearing or water pump shows play/noise, replace the water pump assembly rather than only the pulley.

Step‑by‑step
1) Prepare vehicle
- Cool engine. Disconnect negative battery.
- Raise front of vehicle if needed and secure on jack stands. Remove undertray or splash shields for access.

2) Drain / isolate coolant (optional but recommended)
- You can drain enough coolant to drop the level below the pump/pulley if removing hoses is necessary. Open the radiator drain or remove lower radiator hose into the drain pan. Plug/clamp hoses if you prefer not to drain entire system.

3) Remove obstructing components
- Remove engine cover, fan shroud, drive fan or clutch (if required) and any accessories blocking access to the pump pulley. Note belt routing – take a photo or sketch.

4) Remove accessory belt
- Use a serpentine belt tool or breaker bar on the belt tensioner to relieve tension, then slip the belt off the water pump pulley (or other pulleys as required). Do not allow the tensioner to snap back uncontrolled.

5) Prevent pulley rotation / remove center bolt
- Some pulleys have a large center bolt retaining them. Use an appropriate socket and either:
- Use an impact gun to remove the center bolt (fast and safe if you have one), OR
- Hold the pulley with a strap wrench or pulley holding tool while using a breaker bar to break center bolt loose.
- If bolt and pulley separate, proceed to step 6. If the pulley is held by peripheral bolts, remove those (typically 3 or 4).

6) Remove the pulley
- If the pulley is stuck on the shaft, use a small automotive pulley puller. How to use the puller:
- Choose a puller that fits the pulley lip. Thread the puller center bolt lightly and position the jaws evenly around the pulley lip.
- Tighten the puller center bolt slowly and evenly while keeping the puller centered on the shaft. Apply penetrating oil if stuck.
- Do not pry on the shaft; let the puller do the work. Once the pulley breaks free, remove it and set aside.
- If no puller is available, a strap wrench to twist/remove or careful pry may work but risks damage.

7) Inspect pump, shaft, bearings and seals
- Check pump shaft for play or scoring. Wiggle the pulley shaft; any side‑to‑side or radial play usually means pump bearing is failing — replace the water pump.
- Inspect the mounting surface and keyway for damage. Clean the shaft.

8) Install new pulley
- If replacing pulley only and pump is good, align the pulley on the shaft. If peripheral bolts are used, start bolts by hand.
- Apply medium thread locker if the manufacturer specifies. Tighten bolts in a star pattern evenly.
- Torque bolts to factory spec. If you don’t have the spec: use bolt‑size appropriate torque (approximate guidance only): M6 ≈ 8–12 Nm (6–9 ft‑lb), M8 ≈ 20–25 Nm (15–18 ft‑lb). Confirm with manual.
- If the pulley has a center bolt, torque that bolt to spec as well.

9) Reinstall belt and components
- Reinstall the serpentine belt per routing. Use tensioner tool to slip belt on and ensure it seats correctly on all pulleys.
- Reinstall any removed fan, fan shroud, covers, and undertray.

10) Refill and bleed cooling system
- Refill with specified coolant and bleed air from the cooling system following the bleeding procedure for your engine (open bleed screw if equipped, run engine to thermostat open, top off reservoir).
- Check for leaks around the pulley, weep hole, and hoses.

11) Final checks
- Start engine and observe for belt alignment/noise, leaks, and unusual vibrations. Recheck torque on pulley bolts after initial run (and again after a short test drive).
- Dispose of old coolant and parts properly.

Common pitfalls / what to avoid
- Not confirming whether the pulley is serviceable separately — replacing only the pulley when the pump bearing is bad leads to repeat failure.
- Using excessive force or improper tools and damaging the pump shaft or pulley lip.
- Failing to hold the pulley while loosening the center bolt — can allow the whole pump to spin or damage other components.
- Reusing old bolts that are stretch‑type or corroded — replace if they show wear or if manual specifies replacement.
- Forgetting to record or reproduce belt routing — leads to misrouting and accessory damage.
- Not bleeding the cooling system properly — air pockets cause overheating.
- Over‑torquing or under‑torquing pulley bolts — can strip threads or allow loosening.

Replacement parts checklist
- Water pump pulley (correct part for engine/year)
- Pulley bolts (replace if specified or corroded)
- Serpentine belt (inspect & replace if worn)
- Coolant (correct spec)
- Water pump (if bearing/seal is bad)

Done — follow manufacturer torque/specs and the service manual for your exact model/year whenever possible.
rteeqp73

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