Repair Procedures: Removal

WARNING:

Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage circuit according to the "High Voltage Shut-Off Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries.

NOTE:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump relay removed. And then turn off the ignition switch after engine stops.

Information

Mark all wiring and hoses to avoid mis-connection.

Shut off the high voltage circuit.
(Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT OFF PROCEDURE ")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")
Drain the engine coolant.
(Refer to Cooling System - "COOLANT ")
Drain the inverter coolant.
(Refer to Hybrid Motor System - "COOLANT ")
Disconnect the radiator upper hose (A).

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

Fig 2: Disconnecting Radiator Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the hybrid power control unit (HPCU) and tray.
(Refer to Hybrid Control System - "HYBRID POWER CONTROL UNIT (HPCU) ")
Disconnect the reservoir tank coolant hose (A).

Fig 3: Disconnecting Reservoir Tank Coolant Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the hybrid starter generator (HSG) water hose (A).

Fig 4: Disconnecting Hybrid Starter Generator (HSG) Water Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the electric water pump (EWP) coolant hose (A).

Fig 5: Disconnecting Electric Water Pump (EWP) Coolant Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pump foam (A).

Fig 6: Removing High Pressure Fuel Pump Foam
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).

Fig 7: Disconnecting Fuel Hose And Purge Control Solenoid Valve (PCSV) Hose
Courtesy of KIA MOTORS AMERICA, INC.
Separate the clutch reservoir tank (A).
Tightening Torque :

3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb.ft)

Fig 8: Separating Clutch Reservoir Tank
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine wiring.
1. 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)
2. Disconnect the fuse box main wiring connector (B).
3. Pull the main wiring protector (C) upward to remove it from engine room.
Fig 9: Pulling Main Wiring Protector Upward
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater hose (A).

Fig 10: Disconnecting Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler.
(Refer to Intake and Exhaust System - "MUFFLER ")
Disconnect the wire harness connectors, control cables from the dual clutch transmission.
(Refer to DCT (Dual Clutch Transmission) System - "DCT (DUAL CLUTCH TRANSMISSION ")
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 11: Removing Roll Rod Bracket
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 12: Removing Roll Rod Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the sub frame.
(Refer to Suspension system - "SUB FRAME ")
Support the engine and transaxle assembly on a lift table.
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)

Fig 13: Disconnecting Ground Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine mounting support bracket (A).
Tightening Torque

Nut (B):

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

Bolt (C) and nuts (D):

58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.3 - 54.2 lb.ft)

Fig 14: Removing Engine Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do Not reuse the Bolt C, which is special Bolt coated with bond.
Remove the dual clutch transmission ground cable mounting bolt (A).
Tightening Torque :

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

Fig 15: Removing Dual Clutch Transmission Ground Cable Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle mounting side panel packing (A).

Fig 16: Removing Transaxle Mounting Side Panel Packing
Courtesy of KIA MOTORS AMERICA, INC.
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 17: Removing Transaxle Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine and transaxle assembly by lifting vehicle.

Fig 18: Removing Engine And Transaxle Assembly By Lifting Vehicle
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.