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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.
  1. Disconnect the terminals (A) from battery and remove the battery.
    Fig 1: Locating Battery Terminals
    G06828394Courtesy of KIA MOTORS AMERICA, INC.
  2. Remove the engine cover (A).
    Fig 2: Locating Engine Cover
    G06828395Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the under cover (A).
    Fig 3: Locating Under Cover
    G06828396Courtesy of KIA MOTORS AMERICA, INC.
  4. Drain the engine coolant. (Refer to COOLING SYSTEM )

    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: Locating Intake Air Hose And Air Cleaner Upper Cover
      G06828397Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the ECM connector (A) and ECM connector (B) (A/T only).
    5. Remove the air cleaner element and air cleaner lower cover (C).
      Fig 5: Locating ECM Connector And Air Cleaner Lower Cover
      G06828398Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the battery tray (A).
    Fig 6: Locating Battery Tray
    G06828399Courtesy 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: Locating Upper Radiator Hose, Lower Radiator Hose And ATF Oil Cooler Hoses
    G06828400Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the heater hoses (A).
  10. Disconnect the fuel hose (B).
    Fig 8: Locating Heater Hoses And Fuel Hose
    G06828401Courtesy 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: Locating Accelerator Cable And Throttle Position Sensor Connector
    G06828402Courtesy 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: Locating Rear Oxygen Sensor Connector And Air Conditioner Compressor Switch Connector
      G06828403Courtesy of KIA MOTORS AMERICA, INC.
    6. Remove the wire harness bracket (A).
    7. Disconnect the ISA (Idle Speed Actuator) connector (B).
      Fig 11: Locating Wire Harness Bracket And Idle Speed Actuator Connector
      G06828404Courtesy 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: Locating Front Oxygen Sensor Connector, Crankshaft Position Sensor Connector And Oil Control Valve Connector
      G06828405Courtesy of KIA MOTORS AMERICA, INC.
    11. Disconnect the ignition coil connector (A).
    12. Disconnect the ignition coil condenser connector (B).
    13. Disconnect the CMP (Camshaft Position Sensor) connector (C).
    14. Disconnect the ground cable (D).
    15. Remove the wire harness bracket (E).
      Fig 13: Locating Ignition Coil Connector, Ignition Coil Condenser Connector, Ground Cable And Wire Harness Bracket
      G06828406Courtesy of KIA MOTORS AMERICA, INC.
    16. Remove the ground cable (A) between engine mounting and vehicle body.
      Fig 14: Locating Ground Cable Between Engine Mounting And Vehicle Body
      G06828407Courtesy of KIA MOTORS AMERICA, INC.
    17. Remove the ground cable (A) between transaxle housing and vehicle body.
      Fig 15: Locating Ground Cable Between Transaxle Housing And Vehicle Body
      G06828408Courtesy 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: Locating Transaxle Range Switch Connector, Solenoid Valve Connector And ATF Oil Temperature Sensor Connector
      G06828409Courtesy 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: Locating Vehicle Speed Sensor Connector And Band Server Switch Connector
      G06828410Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the control cable nut (A) from transaxle range switch.
    9. Remove the control cable (B).
      Fig 18: Locating Control Cable Nut And Control Cable
      G06828411Courtesy 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 (C).
      Fig 19: Locating Vehicle Speed Sensor Connector, Neutral Switch Connector And Back-Up Lamp Switch Connector
      G06828412Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the control cable (A).
      Fig 20: Locating Control Cable
      G06828413Courtesy 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: Locating Hose And Brake Booster Vacuum Hose
    G06828414Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the power steering oil hose (A) and drain the power steering oil.
    Fig 22: Locating Power Steering Oil Hose
    G06828415Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the power steering return hose (A).
    Fig 23: Locating Power Steering Return Hose
    G06828416Courtesy of KIA MOTORS AMERICA, INC.
  21. Recovering refrigerant and remove the high & low pressure pipe. (Refer to AIR CONDITIONING SYSTEM air conditioner compressor.
  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: Locating Nuts, Bolt And Engine Mounting Support Bracket
    G06828417Courtesy 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)

    Fig 25: Locating Transaxle Mounting Bracket
    G06828418Courtesy of KIA MOTORS AMERICA, INC.

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

    Fig 26: Locating Wire Harness Protector
    G06828419Courtesy 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: Locating Alternator Connector And "B" Terminal
    G06828420Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the front tires.
  26. Remove the ABS wheel speed sensor (A).
    Fig 28: Locating ABS Wheel Speed Sensor
    G06828421Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the caliper and hang assembly (A).
    Fig 29: Removing Caliper
    G06828422Courtesy of KIA MOTORS AMERICA, INC.
    Fig 30: Hanging Caliper Assembly
    G06828423Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the knuckle mounting bolts (A).
    Fig 31: Locating Knuckle Mounting Bolts
    G06828424Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the steering u-joint mounting bolt (A).
    Fig 32: Locating Steering U-Joint Mounting Bolt
    G06828425Courtesy 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: Locating Front Muffler Heat Protector And Front Muffler
    G06828426Courtesy 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
    G06828427Courtesy 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: Locating Sub Frame Bolts And Nuts
    G06828428Courtesy 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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