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 mis-connection.
Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

Disconnect the battery terminals (A) and ECM connector (B).

Fig 1: Identifying Battery Terminals & ECM Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air intake hose and the air cleaner assembly.
1. Disconnect the breather hose (A).
2. Remove the air cleaner assembly (B).
Fig 2: Identifying Air Cleaner Assembly & Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ECM (A) and battery (B).
Tightening torque:

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

Fig 3: Identifying ECM & Battery
Courtesy of KIA MOTORS AMERICA, INC.
Remove the battery tray (A).
Tightening torque:

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

Fig 4: Identifying Battery Tray
Courtesy of KIA MOTORS AMERICA, INC.
Remove the under covers (A, B).

Fig 5: Identifying Under Covers
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the radiator drain plug (A) and drain engine coolant. Remove the radiator cap to speed draining.

Fig 6: Identifying Radiator Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high & low pressure pipe. (Refer to COMPRESSOR .
Remove the upper radiator hose (A) and lower radiator hose (B).

Fig 7: Identifying Upper Radiator Hose & Lower Radiator Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the accelerator cable (A) and the auto-cruise cable (B) from the cylinder head cover.

Fig 8: Identifying Accelerator Cable & Auto-Cruise Cable
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the engine wiring harness connectors, clamps and hoses.
1. Disconnect the A/C compressor switch connector (A).
2. Disconnect the knock sensor connector (B).
3. Disconnect the TDC sensor connector (C).
4. Disconnect the fuel injector (No. 1) connector (D).
5. Disconnect the fuel injector (No. 2, 3, 4) connector (E).
6. Disconnect the MAP sensor connector (F).
  
  Fig 9: Identifying Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the engine ground line (A).
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 10: Identifying Engine Ground Line
  Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the PCSV connector (A).
9. Disconnect the TPS connector (B).
10. Disconnect the ISCA connector (C).
  
  Fig 11: Identifying Connectors (1 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
11. Disconnect the front heated oxygen sensor connector (A).
12. Disconnect the rear heated oxygen sensor connector (B).
13. Disconnect the oil pressure switch connector (C).
14. Disconnect the CKPS connector (D).
15. Disconnect the OCV connector (E).
16. Disconnect the OTS connector (F).
17. Disconnect the ECTS connector (D).
18. Disconnect the ignition coil connector (E).
19. Disconnect the inhibitor switch connector (F).
  
  Fig 12: Identifying Connectors (2 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
20. Disconnect the brake booster vacuum hose (A).
21. Disconnect the heater hoses (B).
22. Disconnect the fuel inlet hose (C).
23. Disconnect the PCSV hose (D).
  
  Fig 13: Identifying Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle wire, control cable and hose. (Refer to AUTOMATIC TRANSAXLE CONTROL SYSTEM - 2.0L or MANUAL TRANSAXLE SYSTEM - 2.0L )
Remove the blower assembly.
1. Remove the upper radiator hose and cap assembly (A) and lower hose (B).
  Tightening torque:
  
  9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
2. Disconnect the fan motor connector (C).
3. Remove the blower assembly (D).
  
  Fig 14: Identifying Cap Assembly, Lower Hose, Blower Assembly, & Fan Motor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the driveshaft from the front hub assembly. (Refer to DRIVESHAFT ASSEMBLY )
Disconnect the stabilizer bar link. (Refer to FRONT SUSPENSION SYSTEM )
Remove the rear roll stopper (A).
Tightening torque:

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

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

Fig 15: Identifying Rear Roll Stopper & Bolts
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Mark the rear roll stopper direction for proper installation.
Remove the front muffler (A).
Tightening torque:

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

Fig 16: Identifying Front Muffler
Courtesy of KIA MOTORS AMERICA, INC.
Using a floor jack, support the engine and transaxle assembly.
WARNING:
- After removing the mounting bolt (engine and transaxle), 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.
Remove the engine mounting 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 17: Identifying Engine Mounting Bracket, Nuts, & Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle mounting bracket (A).
Tightening torque:

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

Fig 18: Identifying Transaxle Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine and transaxle assembly by lifting vehicle.

Fig 19: Identifying Engine & Transaxle Assembly
Courtesy of KIA MOTORS AMERICA, INC.

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