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. Disconnect the battery negative terminal.
3. Remove the air cleaner assembly.

   (Refer to "AIR CLEANER ")

4. Remove the battery and battery tray.

   (Refer to "BATTERY ")

5. Remove the engine room under cover.

   (Refer to "ENGINE ROOM UNDER COVER ")

6. Drain the engine coolant.

   (Refer to "COOLANT ")

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

   Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the radiator lower hose (A).
   Fig 2: Radiator Lower Hose

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

   (Refer to "COMPRESSOR ")

10. Disconnect the wire harness connectors, control cables and ATF cooler hoses (A/T only) from the transaxle.

    Manual Transaxle:

    (Refer to NA)

    Automatic Transaxle:

    (Refer to "AUTOMATIC TRANSAXLE ")

11. Disconnect the brake booster vacuum hose (A) and heater hoses (B).
    Fig 3: Brake Booster Vacuum Hose & Heater Hoses

    Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
    Fig 4: Fuel & Purge Control Solenoid Valve Hose

    Courtesy of KIA MOTORS AMERICA, INC.
13. Disconnect the control wiring harness connectors and fasteners and remove the wiring harness protector from the engine and transaxle.
    Fig 5: Control Wiring Harness Connectors & Fasteners

    Courtesy of KIA MOTORS AMERICA, INC.
14. Disconnect the front connector (A) and the wiring cables (B) from the fuse box.
    Fig 6: Front Connector & Wiring Cables

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

    (Refer to "MUFFLER ")

16. Remove the roll rod bracket (A).

    Tightening torque 

    Bolt (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 7: Removing Roll Rod Bracket

    Courtesy of KIA MOTORS AMERICA, INC.
17. 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 8: Removing Roll Rod Mounting Support Bracket

    Courtesy of KIA MOTORS AMERICA, INC.
18. Remove the sub frame.

    (Refer to "SUB FRAME ")

19. Support the engine and transaxle assembly with a floor jack.
20. Disconnect the engine ground cable (A).

    Tightening torque: 

    10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)

21. 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 9: Removing Engine Mounting Support Bracket

    Courtesy of KIA MOTORS AMERICA, INC.
22. Disconnect the transaxle ground line (A).
    Fig 10: Transaxle Ground Line

    Courtesy of KIA MOTORS AMERICA, INC.
23. Remove the service cover (A).
    Fig 11: Service Cover

    Courtesy of KIA MOTORS AMERICA, INC.
24. Remove the transaxle mounting bolts (A).

    Tightening torque: 

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

    Fig 12: Transaxle Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
25. Remove the engine and transaxle assembly by lifting vehicle.
    Fig 13: Removing Engine & Transaxle Assembly

    Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:

    • Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
    • When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.