Repair procedures: Removal

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

Mark all wiring and hoses to avoid misconnection.
For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. And then turn off the ignition switch after engine stops.

Remove the engine cover.
Remove the battery and battery tray.
(Refer to "BATTERY ")
Remove the engine room under cover.
(Refer to "ENGINE ROOM UNDER COVER ")
Drain the engine coolant.
(Refer to "COOLANT ")
Disconnect the radiator upper hose (A).

Fig 1: Identifying Radiator Upper Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the radiator lower hose (A).

Fig 2: Identifying Radiator Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing radiator hoses, install as shown in illustrations.

Fig 3: Identifying Radiator Hose Clamps
Courtesy of KIA MOTORS AMERICA, INC.
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
(Refer to "COMPRESSOR ")
Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to "MANUAL TRANSAXLE ")

(Refer to "AUTOMATIC TRANSAXLE ")
Disconnect the brake booster vacuum hose (A) and the heater hoses (B).

Fig 4: Identifying Brake Booster Vacuum Hose And Heater Hoses
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the heater hoses, install as shown in illustrations.

Fig 5: Heater Hose Clip Installation Chart
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

Fig 6: Identifying Purge Control Solenoid Valve Hose And Fuel Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine wirings from the engine room.
1. Remove the (+) cable nut (A).
  Tightening torque:
  
  6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
2. Disconnect the EMS block (B).
3. Disconnect the fuse box connector (C).
4. Disconnect the battery sensor connector (D).
5. Remove the ground bolts (E).
  Tightening torque:
  
  10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
6. Remove the engine wirings from the engine room.
  
  Fig 7: Identifying EMS Block, Fuse Box Connector, Battery Sensor Connector And Ground Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler.
(Refer to "MUFFLER ")
Remove the roll rod bracket (A).
Tightening torque

Nut (B):

107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)

Bolts (C):

49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

Fig 8: Identifying Roll Rod Bracket, Nut And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the roll rod mounting support bracket (A).
Tightening torque:

49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

Fig 9: Identifying Roll Rod Mounting Support Bracket And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the sub frame.
(Refer to "SUB FRAME ")
NOTE:
- After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
- Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
Disconnect the ground cable (A).
Tightening torque:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
Remove the engine mounting support bracket (B).
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 10: Identifying Engine Mounting Support Bracket And Ground Cable
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground line (A).

Fig 11: Identifying Engine Mounting Support Bracket Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Remove the service cover (A), and then slowly loosen the transaxle mounting bolts (B).
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)

Fig 12: Identifying Service Cover
Courtesy of KIA MOTORS AMERICA, INC.

Fig 13: Identifying Transaxle Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine and transaxle assembly by lifting vehicle.
CAUTION:
When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.