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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 misconception.

Disconnect the battery terminals (A) and remove the battery.
Remove the engine cover (B).
Disconnect the ECM connector (C).
Disconnect the breather hose, and then remove the air duct (D) and the air cleaner assembly (E).
Tightening torque:

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

Fig 1: Battery Terminals, Engine Cover, ECM Connector & Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Recover refrigerant and remove the high & low pressure pipe. Refer to REFRIGERANT SYSTEM SERVICE BASICS .
Remove the under covers (A).
Tightening torque:

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

Fig 2: Under Covers
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the drain plug (A), and then drain the engine coolant.
CAUTION: Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

Fig 3: Radiator Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.
Remove the radiator upper hose (A) and lower hose (B).
Remove the heater hoses (C).
Disconnect the brake booster vacuum hose (D).

Fig 4: Radiator Upper/Lower, Heater & Brake Booster Vacuum Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the wiring connectors and harness clamps from the engine.
1. Disconnect the ETC connector (A) and knock sensor connector (B).
2. Disconnect the PCSV connector (C).
3. Disconnect the ECT connector (D).
4. Disconnect the condenser connector (E).
5. Disconnect the CKP sensor connector (F).
6. Disconnect the oxygen sensor connector (G).
  
  Fig 5: ETC, Knock, PCSV, ECT, CKP & Oxygen Sensor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the VCM connector (A) and MAP sensor connector (B). (2.0L SULEV & 2.4 ALL)
  
  Fig 6: VCM & MAP Sensor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the power steering fluid pressure switch connector (A).
9. Disconnect the MAP sensor connector (B).
10. Disconnect the OPS connector (C).
11. Disconnect the alternator connector (D) and 'B' terminal cable from the alternator.
12. Disconnect the A/C switch connector from the compressor.
13. Disconnect the VIS connector.
  
  Fig 7: Power Steering Fluid Pressure Switch, MAP Sensor, OPS & Alternator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
14. Disconnect the intake OCV connector (A).
  
  Fig 8: Intake OCV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
15. Disconnect the CMP sensor connector (A) and the fuel hose (B).
  
  Fig 9: CMP Sensor Connector & Fuel Hose
  Courtesy of KIA MOTORS AMERICA, INC.
16. Disconnect the injector connectors (A) and the ignition coil connectors (B).
  
  Fig 10: Injector & Ignition Coil Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
17. Disconnect the starter connector (A), and cable (B) from the starter.
Fig 11: Starter Cable & Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the transaxle control cable and wiring connectors. Refer to AUTOMATIC TRANSAXLE or MANUAL TRANSAXLE SYSTEM (M6CF3) - 2.0L or MANUAL TRANSAXLE SYSTEM (M6GF2) - 2.4L .
Remove the lower arm (B) & fork (A) mounting bolt (C). Refer to FRONT LOWER ARM .
Tightening torque:

137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

Fig 12: Lower Arm, Fork & Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the lower arm ball joint mounting bolts (A). Refer to FRONT LOWER ARM .
Tightening torque:

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

Fig 13: Lower Arm Ball Joint Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the stabilizer bar link mounting nut (A). Refer to FRONT STABILIZER .
Tightening torque:

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

Fig 14: Stabilizer Bar Link Mounting Nut
Courtesy of KIA MOTORS AMERICA, INC.
Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle. Refer to step 6 under REPAIR PROCEDURES .
Tightening torque:

23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 17.4 ~ 24.6lb-ft)

Fig 15: Tie Rod End
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the driveshaft from the axle hub.
Remove power steering return hose (A) and drain power steering fluid.

Fig 16: Power Steering Return Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove steering u-joint mounting bolt (A). Refer to POWER STEERING GEAR BOX .
Tightening torque:

29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)

Fig 17: Steering U-Joint Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler (A).
Tightening torque:

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

(ULEV)

Fig 18: Front Muffler (ULEV)
Courtesy of KIA MOTORS AMERICA, INC.

(SULEV)

Fig 19: Front Muffler (SULEV)
Courtesy of KIA MOTORS AMERICA, INC.
Support the sub frame (A) with a floor jack, and then remove the stay (B) and sub frame mounting bolts.
Tightening torque:

137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

Fig 20: Sub Frame
Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque:

44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

Fig 21: Stay
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground line and then remove the engine mounting bracket (A).
Tightening torque:

63.7 ~ 107.9N.m (6.5 ~ 11.0kgf.m, 47.0 ~ 79.6lb-ft)

Fig 22: Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground line and then remove the transaxle mounting bracket (A).
Tightening torque:

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

Fig 23: Transaxle Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Lift up the vehicle and remove the engine and transaxle assembly from the bottom of vehicle.

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