Kia Carnival / Sedona factory workshop and repair manual download

- Purpose: clean or service the throttle body on a Kia Carnival / Sedona so the throttle plate and bore move freely and idle/drive performance improves; if cleaning doesn't fix symptoms (rough idle, poor throttle response, throttle fault codes) replacement of the throttle body assembly or related sensors may be required.
- Safety first:
- work on a cool engine in a well-ventilated area, away from open flame; throttle-body cleaner is flammable.
- disconnect the negative battery terminal before touching throttle electrical connectors or the throttle body to avoid electrical shorts or unintended throttle movement.
- wear nitrile gloves and safety glasses; have a fire extinguisher nearby.
- do not force the throttle plate open with tools; avoid damaging the plate or position sensor.
- Basic tools you’ll need (detailed descriptions and how to use them):
- combination wrench set (metric): open-end and box-end wrenches; use the correct size to loosen/tighten bolts and nuts without rounding heads. For bolts in tight spaces use the box end for better grip.
- 1/4" and 3/8" drive ratchet with metric socket set (commonly 8–14 mm): sockets fit over fastener heads; use the ratchet to turn sockets quickly without removing and repositioning; use extensions to reach recessed bolts.
- Torx bits or star screwdriver/bit set (if applicable): many throttle body bolts or hose clamps on Korean cars use Torx; insert bit fully and turn with driver or ratchet adapter to avoid stripping.
- flat-head and Phillips screwdrivers: use the correct tip for hose clamps or cover clips; flat blade is also useful to gently pry vacuum hoses off.
- pliers (needle-nose and regular): to remove spring clamps, small clips and to hold or pull small parts.
- hose clamp pliers or adjustable pliers: for spring-type hose clamps on intake hoses; squeeze and slide clamp back.
- throttle-body or MAF-safe cleaner (aerosol): formulated for throttle bodies and electronic sensors; spray into bore and wipe carbon without leaving residue. Do not use brake cleaner or carb cleaner unless explicitly labeled safe for electronics.
- clean lint-free shop rags and a small soft-bristle brush or toothbrush: rags soak up solvent; brush loosens stubborn carbon.
- replacement gasket or O-ring (throttle body-to-intake): often inexpensive and should be replaced if brittle or compressed; prevents intake leaks.
- small container/tray for bolts and parts: keeps hardware organized.
- Extra but highly recommended tools and why:
- basic OBD2 code reader / scanner (Bluetooth or handheld): reads and clears throttle-related fault codes (P0121, P0122, P2100, P2106, P2111, etc.) and can clear adaptive values; required if ECU requires a throttle relearn or to confirm faults before/after work.
- torque wrench (metered, metric): ensures throttle-body mounting bolts are tightened to manufacturer torque without overtightening and damaging the throttle body or threads.
- service manual or online repair guide for your model/year: gives bolt torque specs, relearn procedure, and exact fastener locations.
- How to use the tools (quick instructions):
- ratchet and socket: pick the correct socket, push onto bolt; use ratchet to turn clockwise to tighten, counterclockwise to loosen; small clicks = ratchet movement.
- wrench: fit box end over nut/bolt, pull toward you to avoid slipping; use correct size to avoid rounding.
- screwdrivers: match tip to screw head; apply steady pressure and turn slowly to avoid cam-out.
- pliers: grip gently and pull; needle-nose for small connectors; don’t use pliers on plastic connector bodies excessively.
- Torx bits: seat fully in screw, keep driver straight, and turn steadily.
- throttle-body cleaner: spray onto rag or directly into bore in short bursts; wipe with rag; do not soak sensors or electrical connectors.
- Preparation steps (before cleaning/removal):
- park, set parking brake, engine off and cool.
- disconnect negative battery terminal and wait 2–3 minutes.
- locate throttle body — follows the intake hose from the airbox to the throttle housing on the intake manifold.
- take photos of connector and hose locations for reference.
- remove air intake ducting between airbox and throttle body by loosening hose clamps with a screwdriver or pliers and removing any mounting bolts.
- Cleaning throttle body (beginner-friendly):
- expose the throttle body by removing intake duct so you see the throttle plate and bore.
- with the ignition OFF and battery disconnected, manually open throttle slightly by hand if necessary to access rear of plate—do this gently; some throttle bodies have return springs so avoid forcing.
- spray throttle-body cleaner onto a clean rag and wipe carbon from the throttle plate and bore; repeat until clean. For heavy deposits, spray directly in short bursts and use a soft-bristle brush to loosen deposits, then wipe.
- avoid spraying electrical connectors or the throttle position sensor; keep cleaner away from wiring harness.
- after cleaning, wipe dry with a clean rag and let solvent evaporate (a few minutes).
- reassemble intake duct, reconnect hoses and clamps, reconnect negative battery.
- Throttle relearn / reset (why and options):
- why: modern electronic throttles adapt to airflow and plate position; after cleaning or battery disconnect the ECU may need to relearn idle and throttle position. Without relearn you may get rough idle or engine light.
- recommended: use an OBD2 scanner to clear throttle-related codes and perform any manufacturer-specified throttle relearn procedure.
- manual basic relearn (if no scanner available; may vary by year/model; if engine light persists use scanner or dealer):
- with engine off, turn ignition to ON (do not start) for ~5–10 seconds then OFF for ~5 seconds, repeat 3 times; start engine and let idle untouched for 5–10 minutes to allow ECU to adapt. (If symptoms persist, use scan tool/manual.)
- When replacement is required, why, and what to replace:
- symptoms indicating replacement:
- persistent throttle-related trouble codes that don’t clear after cleaning/relearn.
- physical damage to throttle plate or housing, stuck plate that won’t move, burnt/melting connectors, or cracked housing.
- severe electronic failure (throttle position sensor or motor failure) where ECU requests a replaced part.
- parts that might be needed:
- throttle body assembly (OEM part recommended): includes throttle plate, motor/actuator, position sensors; replacement required if electronic/actuator fails or housing is damaged.
- throttle body gasket or O-ring: always replace if removed or if old is brittle — prevents intake vacuum leaks that cause rough idle.
- wiring harness/connector repair kit or replacement connector: if wires or connectors are corroded or damaged.
- MAF sensor (if equipped and if MAF-related codes are present): sometimes mistaken for throttle issues; inspect and replace if faulty.
- replacement steps (overview for a beginner; follow manual for bolt torque):
- disconnect negative battery.
- remove intake ducting and disconnect electrical connector and any vacuum hoses from throttle body.
- unbolt throttle body (use correct sockets/Torx); support unit so it doesn’t fall.
- remove old gasket; clean mating surfaces.
- fit new gasket, position new throttle body, hand-start bolts, then tighten gradually in a crisscross pattern to spec (if no torque wrench, snug but do not over-torque).
- reconnect electrical connector and hoses, reattach intake ducting, reconnect battery.
- use OBD2 scanner to clear codes and perform throttle relearn if available.
- Testing after work:
- start engine, let idle and warm up; listen for unusual noises, check for rough idle or check-engine light.
- if check-engine light appears, use OBD2 scanner to read codes and act accordingly.
- road-test gently to confirm throttle response improved.
- Troubleshooting tips:
- persistent idle or throttle faults after cleaning—scan for codes; if code points to throttle actuator or position sensor, replacement likely needed.
- vacuum leak after reassembly—recheck hose connections and gasket seating.
- if unsure about electrical faults, have a technician diagnose; replacing an expensive throttle body unnecessarily can waste money.
- Quick parts/consumables checklist to buy before starting:
- throttle-body cleaner (spray),
- new throttle body gasket/O-ring,
- small shop rags, soft brush,
- basic metric socket set and screwdrivers,
- OBD2 code reader (basic scanner) — highly recommended.
- Final practical notes:
- take photos during disassembly for reference.
- do not use excessive force on electrical connectors or throttle plate.
- if you are not comfortable removing the throttle body or interpreting codes, have a qualified mechanic complete the job.


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