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Repair Procedures: Removal

NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  • For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. And then turn off the ignition switch after engine stops.

Information 

Mark all wiring and hoses to avoid misconnection.

  1. Remove the engine cover.

    (refer to Engine And Transaxle Assembly - "Engine Cover ")

  2. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  3. Remove the engine control module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  4. Remove the battery tray.

    (Refer to Engine Electrical System - "BATTERY ")

  5. Remove the air duct and air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  6. Remove the engine room under cover.

    (refer to Engine And Transaxle Assembly - "Engine Room Under Cover ")

  7. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  8. Remove the intercooler inlet hoses & pipe (A).

    Tightening torque 

    Bolts:

    19.6 - 26.4 N.m (2.0 - 2.7 kgf.m, 14.4 - 19.5 lb.ft)

    Clamp:

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 1: Locating Intercooler Inlet Hoses & Pipe
    G12238243Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the intercooler outlet hose (A).

    Tightening torque  :

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 2: Locating Intercooler Outlet Hose
    G12238244Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the radiator upper hose (A).
    Fig 3: Locating Radiator Upper Hose
    G12238245Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the RCV solenoid valve hose (A).
    Fig 4: Locating RCV Solenoid Valve Hose
    G12238246Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the radiator lower hose (A).
    Fig 5: Locating Radiator Lower Hose
    G12238247Courtesy of KIA MOTORS AMERICA, INC.
  13. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

    (Refer to Heating, Ventilation Air conditioning - "COMPRESSOR ")

  14. Remove the double clutch Transaxle wiring harness connectors and control cable from the transaxle.

    (Refer to Dual Clutch Transaxle (DCT) - "DUAL CLUTCH TRANSMISSION ASSEMBLY ")

  15. Disconnect the brake booster vacuum hose (A) and heater hoses (B).
    Fig 6: Locating Brake Booster Vacuum Hose And Heater Hoses
    G12238248Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
    Fig 7: Locating Fuel Hose And Purge Control Solenoid Valve Hose
    G12238249Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the control wiring harness connectors and fasteners and remove the wiring harness protectors from the engine and transaxle.
    Fig 8: Control Wiring Harness Connectors And Fasteners
    G12238250Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the battery wiring harness connector (A) and cables (B) from the junction box.
    Fig 9: Locating Battery Wiring Harness Connector And Cables
    G12238251Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the front muffler.

    (Refer to Intake And Exhaust System - "MUFFLER ")

  20. Remove the roll rod bracket (A).

    Tightening torque 

    Bolt (B):

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

    Bolts (C):

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

    Fig 10: Locating Roll Rod Bracket And Bolts
    G12238252Courtesy of KIA MOTORS AMERICA, INC.
  21. 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 11: Locating Roll Rod Mounting Support Bracket With Bolts
    G12238253Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the sub frame.

    (Refer to Suspension system - "SUB FRAME ")

  23. Support the engine and transaxle assembly with a lift table.
  24. Disconnect the engine ground cable (A).
    Fig 12: Locating Engine Ground Cable
    G12238254Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the engine mounting support bracket (A).

    Tightening torque 

    Nut (B):

    78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb.ft)

    Bolt (C), Nuts (D):

    58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.4 - 54.2 lb.ft)

    Fig 13: Locating Engine Mounting Support Bracket, Nuts And Bolts
    G12238255Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the service cover (A).
    Fig 14: Locating Service Cover
    G12238256Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the double clutch Transaxle mounting bolts (A).

    Tightening torque  :

    88.3 - 107.9 N.m (7.0 - 11.0 kgf.m, 65.1 - 79.6 lb.ft)

    Fig 15: Locating Double Clutch Transaxle Mounting Bolts
    G12238257Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the engine and Transaxle assembly (A) by lifting vehicle.
    Fig 16: Removing Engine And Transaxle Assembly By Lifting Vehicle
    G12238258Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
    • When removing the engine and Transaxle assembly, be careful not to damage any surrounding parts or body components.
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