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.
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.

Remove the engine cover (A).

Fig 1: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the battery terminals (A). Disconnect the negative terminal first.
Tightening torque

(+) terminal:

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

(-) terminal (without battery sensor):

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

(-) terminal (with battery sensor):

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

Fig 2: Identifying Battery Terminals
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Remove the air duct (A).
2. Disconnect the breather hose (B).
3. Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 3: Identifying Air Duct, Breather Hose, Air Intake Hose And Y
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  - Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
  Fig 4: Identifying Air Intake Hose Groove
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the battery (A) after removing the mounting bracket.
Tightening torque:

8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

Fig 5: Identifying Battery
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ECM connectors (A) and then remove the ECM (B) and the battery tray (C).
Tightening torque

ECM bracket bolts&nut:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Battery tray bolts:

8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

Fig 6: Identifying ECM Connectors, ECM And Battery Tray
Courtesy of KIA MOTORS AMERICA, INC.
Remove the under cover (A).
Tightening torque:

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

Fig 7: Identifying Under Cover Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to COOLING SYSTEM in this group)
Disconnect the radiator upper hose (A) and lower hose (B).

Fig 8: Identifying Radiator Upper Hose
Courtesy of KIA MOTORS AMERICA, INC.

Fig 9: Identifying Radiator Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Install the radiator hoses as shown illustrations.

Fig 10: Identifying Radiator Hose Installation Position
Courtesy of KIA MOTORS AMERICA, INC.
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe (A). (Refer to AIR CONDITIONING SYSTEM in HA Group.)

Fig 11: Identifying Refrigerant Low Pressure Pipe Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the (+) cable (A) from the fuse/relay box.

Fig 12: Identifying (+) Cable Of Fuse/Relay Box
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.
1. The A/C compressor switch connector (A) and the alternator connector (B)
  
  Fig 13: Identifying A/C Compressor Switch Connector And Alternator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. The intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B)
  
  Fig 14: Identifying Intake OCV (Oil Control Valve) Connector And Exhaust OCV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
3. The ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D)
  
  Fig 15: Identifying Ignition Coil Connectors, Injector Extension Connector, VIS Connector And PCSV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
4. The FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C)
  
  Fig 16: Identifying FPCV Connector, Intake CMPS Connector And Exhaust CMPS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. The oxygen sensor connectors (A) and the condenser connector (B)
  
  Fig 17: Identifying Oxygen Sensor Connectors And Condenser Connector
  Courtesy of KIA MOTORS AMERICA, INC.
6. The ECTS (Engine coolant temperature sensor) connector (A) and the ground line (B)
  
  Fig 18: Identifying ECTS Connector And Ground Line
  Courtesy of KIA MOTORS AMERICA, INC.
7. The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor)&IATS (Intake air temperature sensor) connector (B)
  
  Fig 19: Identifying ETC Connector And MAPS & IATS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
8. The knock sensor connector (A), the CKPS (Crankshaft position sensor) connector (B), the front connector (C), the starter connector (D) and the oil pressure connector (E)
Fig 20: Identifying Knock Sensor Connector, CKPS Connector, Front Connector, Starter Connector And Oil Pressure Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to REMOVAL .
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).

Fig 21: Identifying Fuel Hose And PCSV (Purge Control Solenoid Valve) Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the brake booster vacuum hose (A) and the heater hose (B).

Fig 22: Identifying Brake Booster Vacuum Hose And Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Install the heater hoses as shown illustrations.

Fig 23: Identifying Heater Hoses Installation Position
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ATF cooler hoses (A). (Refer to REMOVAL .

Fig 24: Identifying ATF Cooler Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler (A) after removing the rear oxygen sensor connector from the bracket.
Tightening torque:

39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

Fig 25: Identifying Front Muffler
Courtesy of KIA MOTORS AMERICA, INC.
Remove the steering u-joint mounting bolt (A). (Refer to STEERING COLUMN AND SHAFT .

Fig 26: Identifying Steering U-Joint Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front wheels. (Refer to WHEEL .
Remove the lower arms (A). (Refer to FRONT LOWER ARM .

Fig 27: Identifying Lower Arms
Courtesy of KIA MOTORS AMERICA, INC.
Remove the stabilizer bar links (A). (Refer to FRONT STABILIZER LINK .

Fig 28: Identifying Stabilizer Bar Links
Courtesy of KIA MOTORS AMERICA, INC.
Remove the tie rod ends (A). .

Fig 29: Identifying Tie Rod Ends
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the drive shafts from the axle hubs. (Refer to FRONT AXLE ASSEMBLY .
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)

Bolt (C):

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

Fig 30: Identifying Roll Rod Bracket And Nut
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 31: Identifying Roll Rod Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. (Refer to SUB FRAME .
Tightening torque

Sub frame mounting bolts&nuts:

156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

Sub frame stay mounting bolts:

44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)

Fig 32: Identifying Sub Frame
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall downward. Securely support the assemblies with floor jack.
- Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
Disconnect the ground line (A) and then remove the engine mounting support bracket (B).
Tightening torque

Ground line bolt:

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

Nut (C):

63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

Bolt (D) and nuts (E):

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

Fig 33: Identifying Ground Line And Engine Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground line (A), and then remove the transaxle mounting bracket bolts (B).
Tightening torque:

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

Fig 34: Identifying Ground Line And Transaxle Mounting Bracket Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine and transaxle assembly (A) by lifting vehicle.

Fig 35: Identifying Engine And Transaxle Assembly
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.