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.
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.

Disconnect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
Remove the engine cover (B).
Remove the radiator grille upper cover (C).

Fig 1: Battery Negative Terminal, Engine Cover & Radiator Grille Upper Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A) and the BARO (Barometric pressure) sensor connector (B).
2. Disconnect the air intake hose and then remove the air cleaner assembly (C).
  Tightening torque
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 2: Breather Hose, BARO Sensor Connector & Air Cleaner Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the battery positive terminal (A) and then remove the battery clamp (B), battery (C).
Tightening torque:

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

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

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

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

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

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

Fig 6: Radiator Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.

WARNING: 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.
Remove the radiator upper hose (A) and lower hose (B).

Fig 7: Upper & Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the RH rear oxygen sensor connector (A).

Fig 8: Right Rear Oxygen Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the LH rear oxygen sensor connector (A).

Fig 9: Left Rear Oxygen Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure pipe and low pressure pipe. Refer to REFRIGERANT LINE .
Disconnect the engine wiring.
1. Remove the engine room fuse and relay box cover (A).
2. Disconnect the ECM connectors (B).
3. Disconnect the FAM connectors (C).
  
  Fig 10: Relay Box Cover
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the FAM mounting bolts (A) and take the FAM (B) out of the splash shield (C).
5. Disconnect the connector (D) from the splash shield (C).
  
  Fig 11: FAM, Mounting Bolts, Splash Shield & Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the front connector (A).

Fig 12: Front Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle wire harness connectors and control cable from the transaxle. Refer to REMOVAL .
Disconnect the heater hose (A).

Fig 13: Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the PCSV hose (A), fuel hose (B), brake booster vacuum hose (C).

Fig 14: PCSV Hose, Fuel Hose & Brake Booster Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the power steering pump hose, and disconnect the power steering return hose. Refer to POWER STEERING HOSE .
Remove the radiator support upper member assembly (A) for convenience sake.
Tightening torque:

0.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 7.9 lb-ft)

Fig 15: Radiator Support Upper Member Assembly
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: The bottom side bolt (A) which can be seen after removing the under cover should be loosened for removal of the radiator support upper member assembly.

Fig 16: Bottom Side Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler (A).
Tightening torque:

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

Fig 17: Front Muffler
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front wheels.
Remove the shock absorbers, the stabilizer bar links and the tie rod ends. Refer to FRONT SUSPENSION SYSTEM .
Disconnect the drive shafts from the axle hub. Refer to FRONT DRIVESHAFT .
Remove the steering u-joint mounting bolt (A). Refer to STEERING COLUMN-SHAFT .

Fig 18: Steering U-Joint Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts.
Tightening torque:

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

Bolts (B): 156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)

Fig 19: Sub Frame & Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground cable (A), and then remove the engine mounting bracket (B).
Tightening torque:

Bolts (C) & Nut (D):

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

Fig 20: Ground Cable & Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground cable (A), and then remove the transaxle mounting bracket through bolt (B).
Tightening torque:

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

Fig 21: Ground Cable & Transaxle Mounting Bracket Through Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine and transaxle assembly by lifting vehicle.
CAUTION: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.