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Home >> Kia >> 2006 >> Rio Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> Engine Overhaul >> Engine And Transaxle Assembly >> Removal
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Engine And Transaxle Assembly: 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.
  1. Disconnect the terminals (A) from battery and remove the battery.
    Fig 1: Identifying Battery Terminals
    G04861680Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the engine cover (A).
    Fig 2: Identifying Engine Cover
    G04861605Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the under cover (A).
    Fig 3: Identifying Under Cover
    G04861682Courtesy of KIA MOTORS AMERICA, INC.
  4. Drain the engine coolant. (Refer to ENGINE COOLANT REFILLING AND BLEEDING  ) Remove the radiator cap to speed draining.
  5. Remove the intake air hose and air cleaner assembly.
    1. Disconnect the AFS (Air Flow Sensor) connector (A).
    2. Disconnect the breather hose (B) from intake air hose (D).
    3. Remove the intake air hose (D) and air cleaner upper cover (C).
      Fig 4: Identifying Intake Air Hose And Air Cleaner Upper Cover
      G04861683Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the ECM connector (A) and ECM connector (B) (All only).
    5. Remove the air cleaner element and air cleaner lower cover (C).
      Fig 5: Identifying Air Cleaner Element And Air Cleaner Lower Cover
      G04861684Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the battery tray (A).
    Fig 6: Identifying Battery Tray
    G04861685Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the upper radiator hose (A) and lower radiator hose (B).
  8. Disconnect the ATF oil cooler hoses (C).
    Fig 7: Identifying ATF Oil Cooler Hoses
    G04861755Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the heater hoses (A).
  10. Disconnect the fuel hose (B).
    Fig 8: Identifying Fuel Hose
    G04861687Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
  12. Disconnect the TPS (Throttle Position Sensor) connector (B).
    Fig 9: Identifying Throttle Position Sensor Connector
    G04861688Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
    1. Disconnect the rear oxygen sensor connector (A).
    2. Disconnect the air conditioner compressor switch connector (B).
    3. Disconnect the knock sensor connector (C).
    4. Disconnect the injector connectors (No.3,4) (D).
    5. Disconnect the injector connectors (No.1,2) (E)
      Fig 10: Identifying Injector Connectors
      G04861689Courtesy of KIA MOTORS AMERICA, INC.
    6. Remove the wire harness bracket (A).
    7. Disconnect the ISA (Idle Speed Actuator) connector (B).
      Fig 11: Identifying Idle Speed Actuator Connector
      G04861690Courtesy of KIA MOTORS AMERICA, INC.
    8. Disconnect the front oxygen sensor connector (A).
    9. Disconnect the CKP (Crankshaft Position Sensor) connector (B).
    10. Disconnect the OCV (Oil Control Valve) connector (C).
      Fig 12: Identifying Oil Control Valve Connector
      G04861691Courtesy of KIA MOTORS AMERICA, INC.
    11. Disconnect the ignition coil connector (A).
    12. Disconnect the ignition coil condenser connector (A).
    13. Disconnect the CMP (Camshaft Position Sensor) connector (C).
    14. Disconnect the ground cable (D).
    15. Remove the wire harness bracket (E).
      • 1.6 CVVT 
        Fig 13: Identifying Wire Harness Bracket
        G04861692Courtesy of KIA MOTORS AMERICA, INC.
    16. Remove the ground cable (A) between engine mounting and vehicle body.
      Fig 14: Identifying Ground Cable Between Engine Mounting And Vehicle Body
      G04861762Courtesy of KIA MOTORS AMERICA, INC.
    17. Remove the ground cable (A) between transaxle housing and vehicle body.
      Fig 15: Identifying Ground Cable Between Transaxle Housing And Vehicle Body
      G04861763Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the transaxle wire harness connectors and control cable from transaxle (A/T).
    1. Disconnect the transaxle range switch connector (A).
    2. Disconnect the solenoid valve connector (B).
    3. Disconnect the ATF oil temperature sensor connector (C).
      Fig 16: Identifying ATF Oil Temperature Sensor Connector
      G04861764Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the vehicle speed sensor connector (A).
    5. Disconnect the band server switch connector (B).
    6. Disconnect the pulse generator (A) connector (C).
    7. Disconnect the pulse generator (B) connector (D).
      Fig 17: Identifying Pulse Generator Connector
      G04861765Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the control cable nut (A) from transaxle range switch.
    9. Remove the control cable (B).
      Fig 18: Identifying Control Cable
      G04861766Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the transaxle wire harness connectors and control cable from transaxle (M/T).
    1. Disconnect the vehicle speed sensor connector (A).
    2. Disconnect the neutral switch connector (B).
    3. Disconnect the back-up lamp switch connector (A).
      Fig 19: Identifying Back-Up Lamp Switch Connector
      G04861767Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the control cable (A).
      Fig 20: Identifying Control Cable
      G04861768Courtesy of KIA MOTORS AMERICA, INC.
  16. Move the disconnected wire harnesses to the fuse box side so as to prevent interfering with other parts.
  17. Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
  18. Remove the brake booster vacuum hose (B).
    Fig 21: Identifying Brake Booster Vacuum Hose
    G04861693Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the power steering oil hose (A) and drain the power steering oil.
    Fig 22: Identifying Power Steering Oil Hose
    G04861770Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the power steering return hose (A).
    Fig 23: Identifying Power Steering Return Hose
    G04861771Courtesy of KIA MOTORS AMERICA, INC.
  21. Recovering refrigerant and remove the high & low pressure pipe. (Refer to AIR CONDITIONING SYSTEM )
  22. Remove the nuts (B, D), bolt (C) and engine mounting support bracket (A).

    Tightening torque:

    Nut (B): 68.6~93.2N.m (7.0~9.5kgf.m, 50.6~68.7lb-ft)

    Bolt (C), Nut (D): 49.0~63.7N.m (5.0~6.5kgf.m,36.2~47.0lb-ft)

    Fig 24: Identifying Nuts, Bolt And Engine Mounting Support Bracket
    G04861772Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the transaxle mounting bracket (A).

    Tightening torque:

    Bolt, Nut (B):

    68.6~93.2N.m (7.0~9.5kgf.m, 50.6~68.7lb-ft)

    • AT 
      Fig 25: Identifying Transaxle Mounting Bracket
      G04861773Courtesy of KIA MOTORS AMERICA, INC.

      * A/T: Remove the wire harness protector (B) on the transaxle mounting support bracket.

    • M/T 
      Fig 26: Identifying Wire Harness Protector
      G04861774Courtesy of KIA MOTORS AMERICA, INC.

    * M/T: Remove the clutch release cylinder oil hose (B) on the transaxle mounting support bracket.

  24. Disconnect the alternator connector (A) and "B" terminal (B).
    Fig 27: Identifying Alternator Connector And "B" Terminal
    G04861775Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the front tires.
  26. Remove the ABS wheel speed sensor (A).
    Fig 28: Identifying ABS Wheel Speed Sensor
    G04861776Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the caliper and hang assembly (A).
    Fig 29: Identifying Caliper
    G04861777Courtesy of KIA MOTORS AMERICA, INC.
    Fig 30: Hanging Assembly
    G04861778Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the knuckle mounting bolts (A).
    Fig 31: Identifying Knuckle Mounting Bolts
    G04861779Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the steering u-joint mounting bolt (A).
    Fig 32: Identifying Steering U-Joint Mounting Bolt
    G04861780Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the front muffler heat protector (A).
  31. Remove the front muffler (B).

    Tightening torque:

    29.4~39.2N.m (3.0~4.0kgf.m, 21.7~28.9lb-ft)

    Fig 33: Identifying Front Muffler
    G04861781Courtesy of KIA MOTORS AMERICA, INC.
  32. Using a floor jack, support the engine and transaxle assembly.
    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.
    Fig 34: Supporting Engine And Transaxle Assembly
    G04861782Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the sub frame bolts and nuts.

    Tightening torque:

    Bolt (A), Nut (B):

    93.2~117.7N.m (9.5~12.0kgf.m, 68.7~86.8lbf.ft)

    Fig 35: Identifying Sub Frame Bolts And Nuts
    G04861783Courtesy of KIA MOTORS AMERICA, INC.
  34. 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.
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