Repair Procedures: Removal

1. Remove the front wheel and tire (A) from front hub.

   Tightening torque: 

   88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

   CAUTION: Be careful not to damage the hub bolts when removing the front wheel and tire (A).
   Fig 1: Removing Front Wheel And Tire With Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the stabilizer link (B) with the front strut assembly (A) after loosening the nut.

   Tightening torque: 

   98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

   Fig 2: Removing Stabilizer Link & Front Strut Assembly With Nut

   Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the tie rod end ball joint (C) from the knuckle by using the SST (09568-34000).
   1. Remove the split pin (A).
   2. Remove the castle nut (B).
   3. Use the SST (09568-34000).

   Tightening torque: 

   34.3 ~ 44.1 N.m (3.5 ~ 4.5 kgf.m, 25.3 ~ 32.5 lb-ft)

   Fig 3: Locating Tie Rod End Ball Joint, Split Pin And Castle Nut

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 4: Removing Tie Rod End Ball Joint From Knuckle Using SST (09568-34000)

   Courtesy of KIA MOTORS AMERICA, INC.
   CAUTION:

   • When using SST, be sure not to damage the dust cover of lower arm ball joint.
   • Keep SST tied to the car as there is a risk of injury by dropping the SST when removing the lower arm ball joint.
   • Be sure to use SST as the peripheral parts may be damaged when the lower arm ball joint is removed by using a general tool such as lever.
4. Loosen the bolt & nut and then remove the lower arm (A).

   Tightening torque: 

   98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

   Fig 5: Removing Lower Arm With Bolt & Nut

   Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the front lower arm from the front knuckle using the SST (0K545-A9100).
   1. After removing bolts from the front knuckle, install and tighten the sub body bolt (A).
      Fig 6: Locating Sub Body Bolt

      Courtesy of KIA MOTORS AMERICA, INC.
   2. Input the sub body (A) between the front knuckle and the sub body bolt.
   3. Tighten bolt (B) of the sub body bolt to broaden the gap of the front knuckle.
      Fig 7: Locating Sub Body

      Courtesy of KIA MOTORS AMERICA, INC.
   4. Install the safe wire (A).
      Fig 8: Locating Safe Wire

      Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Install a safe wire on the front strut to prevent dropping the SST and hurting technicians.
   5. Install the main body, between the front strut and the lower arm.
      Fig 9: Installing Main Body Between Front Strut & Lower Arm

      Courtesy of KIA MOTORS AMERICA, INC.
   6. To avoid the main body coming off, install a fixing clamp (A) beside the main body.
      Fig 10: Locating Fixing Clamp

      Courtesy of KIA MOTORS AMERICA, INC.
   7. After installing a fixing clamp, rotate the handle (B) clock wise till the clamp is fixed on a lower arm.
      Fig 11: Rotating Handle Clockwise

      Courtesy of KIA MOTORS AMERICA, INC.
   8. Tighten a main body bolt (A) of the slowly and remove the lower arm from the front knuckle.
   Fig 12: Locating Main Body Bolt

   Courtesy of KIA MOTORS AMERICA, INC.
6. Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.

   Tightening torque: 

   32.4 ~ 37.3N.m (3.3 ~ 3.8kgf.m, 23.9 ~ 27.5lb-ft)

   CAUTION:

   • Keep the gear in the neutral range to prevent any damage on the clock spring inner cable while handling the steering wheel.
   • Do not reuse the bolt.
   Fig 13: Removing Universal Joint Assembly Bolt

   Courtesy of KIA MOTORS AMERICA, INC.
7. Remove the under cover.

   (Refer to "ENGINE ROOM UNDER COVER ")

8. Remove the roll rod stopper bolt (A).

   Tightening torque: 

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

   CAUTION: Bolt (A) is a special bolt only for bolt and is not to be reused.
   Fig 14: Removing Roll Rod Stopper Bolt

   Courtesy of KIA MOTORS AMERICA, INC.
9. Disconnect the muffler rubber hanger (A).
   Fig 15: Locating Muffler Rubber Hanger

   Courtesy of KIA MOTORS AMERICA, INC.
10. Loosen the bolts & nuts and then remove the sub frame.

    Tightening torque 

    Bolts: 

    1. 44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)
    2. 176.5 ~ 196.1 N.m (18.0 ~ 20.0 kgf.m, 115.7 ~ 144.7lb-ft)

       Nuts: 

    3. 44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)
    4. 176.5 ~ 196.1 N.m (18.0 ~ 20.0 kgf.m, 115.7 ~ 144.7lb-ft)
    Fig 16: Locating Sub Frame Bolts And Nuts

    Courtesy of KIA MOTORS AMERICA, INC.
11. Remove the R-MDPS connector. (Only R-MDPS)
12. Loosen four (4) bolts (A) and then remove the stabilizer bar (B) from the sub frame.

    Tightening torque: 

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

    Fig 17: Locating Stabilizer Bar And Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
13. Loosen the bolt and then remove the protector (A).

    Tightening torque: 

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

    Fig 18: Locating Protector With Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
14. Remove the steering gearbox (B) from the cross member by loosening four (4) mounting bolts.

    Tightening torque: 

    88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)

    Fig 19: Locating Steering Gearbox And Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
15. Loosen two (2) nuts (A) and then remove the sub frame damper (B).

    Tightening torque: 

    39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)

    Fig 20: Locating Sub Frame Damper And Nuts

    Courtesy of KIA MOTORS AMERICA, INC.
16. Remove the front lower arm.

    (Refer to "FRONT LOWER ARM ")

17. Loosen two (2) bolts (A) and then remove the roll rod stopper (B) from the sub frame (C).

    Tightening torque: 

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

    Fig 21: Removing Roll Rod Stopper And Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
    Fig 22: Locating Sub Frame

    Courtesy of KIA MOTORS AMERICA, INC.
18. Install in the reverse order of removal.
19. Check the wheel Alignment.

(Refer to "ALIGNMENT ")