Repair procedures: Removal

Information 

• 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.

1. Remove the engine cover.
2. Remove the battery and battery tray.

   (Refer to "BATTERY ")

3. Remove the engine room under cover.

   (Refer to "ENGINE ROOM UNDER COVER ")

4. Drain the engine coolant.

   (Refer to "COOLANT ")

5. Disconnect the radiator upper hose (A).
   Fig 1: Identifying Radiator Upper Hose

   Courtesy of KIA MOTORS AMERICA, INC.
6. 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 Hoses

   Courtesy of KIA MOTORS AMERICA, INC.
7. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

   (Refer to "COMPRESSOR ")

8. Remove the transaxle wire harness connectors and control cable from the transaxle.

   (Refer to "MANUAL TRANSAXLE ")

   (Refer to "AUTOMATIC TRANSAXLE ")

9. 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: Identifying Heater Hoses Angle And Dimensions

   Courtesy of KIA MOTORS AMERICA, INC.
10. 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.
11. 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 Cable Nut, EMS Block, Fuse Box Connector, Battery Sensor Connector And Ground Bolts

       Courtesy of KIA MOTORS AMERICA, INC.
12. Remove the front muffler.

    (Refer to "MUFFLER ")

13. 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

    Courtesy of KIA MOTORS AMERICA, INC.
14. 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

    Courtesy of KIA MOTORS AMERICA, INC.
15. 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.
16. 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)

17. 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.
18. Disconnect the ground line (A).
    Fig 11: Identifying Ground Line Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
19. 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.
20. Remove the engine and transaxle assembly by lifting vehicle.
    NOTE: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.