Engine and Transaxle Assembly: Removal & Installation Kia Forte I

Removal

Note. Mark all wiring and hoses to avoid misconnection.

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1. Disconnect the battery terminals (A) and remove the battery.
2. Remove the engine cover (B).
3. Disconnect the ECM connector (C).
4. 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)
5. Recover refrigerant and remove the high & low pressure pipe. (Refer to «AIR CONDITIONING SYSTEM»(ref-362288) ).
6. Remove the under covers (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
7. 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.
8. Remove the radiator upper hose (A) and lower hose (B).
9. Remove the heater hoses (C).
10. Disconnect the brake booster vacuum hose (D).
11. Disconnect the wiring connectors and harness clamps from the engine. Disconnect the ETC connector (A) and knock sensor connector (B). Disconnect the PCSV connector (C). Disconnect the ECT connector (D). Disconnect the condenser connector (E). Disconnect the CKP sensor connector (F). Disconnect the oxygen sensor connector (G). Disconnect the VCM connector (A) and MAP sensor connector (B). (2.0L SULEV & 2.4 ALL) Disconnect the power steering fluid pressure switch connector (A). Disconnect the MAP sensor connector (B). Disconnect the OPS connector (C). Disconnect the alternator connector (D) and 'B' terminal cable from the alternator. Disconnect the A/C switch connector from the compressor. Disconnect the VIS connector. Disconnect the intake OCV connector (A). Disconnect the CMP sensor connector (A) and the fuel hose (B). Disconnect the injector connectors (A) and the ignition coil connectors (B). Disconnect the starter connector (A), and cable (B) from the starter.
12. Disconnect the transaxle control cable and wiring connectors. (For Automatic Transaxle, refer to «AUTOMATIC TRANSAXLE CONTROL SYSTEM - A4CF2»(ref-362223) or «AUTOMATIC TRANSAXLE CONTROL SYSTEM - A5CF2»(ref-362228) . For Manual Transaxle, refer to «MANUAL TRANSAXLE SYSTEM- M5CF3»(ref-362217) or «MANUAL TRANSAXLE SYSTEM - M6GF2»(ref-362292) .)
13. Remove the lower arm (B) & fork (A) mounting bolt (C). (Refer to «FRONT SUSPENSION SYSTEM»(ref-362234) ) Tightening torque: 137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)
14. Remove the lower arm ball joint mounting bolts (A). (Refer to «FRONT SUSPENSION SYSTEM»(ref-362234) ) Tightening torque: 98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)
15. Remove the stabilizer bar link mounting nut (A). (Refer to «FRONT SUSPENSION SYSTEM»(ref-362234) ) Tightening torque: 98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)
16. Remove the split pin and castle nut and then disconnect the tie rod end (A) from the knuckle. (Refer to «HYDRAULIC POWER STEERING SYSTEM»(ref-362240) or «ELECTRIC POWER STEERING»(ref-362239) ) Tightening torque: 23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 17.4 ~ 24.6lb-ft)
17. Disconnect the driveshaft from the axle hub.
18. Remove power steering return hose (A) and drain power steering fluid.
19. Remove steering universal joint mounting bolt (A). (Refer to «HYDRAULIC POWER STEERING SYSTEM»(ref-362240) or «ELECTRIC POWER STEERING»(ref-362239) ) Tightening torque: 29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)
20. Remove the front muffler (A). Tightening torque: 39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4 b-ft) [ULEV] [SULEV]
21. 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) Tightening torque: 44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)
22. Disconnect the ground line and then remove the engine mounting bracket (A). Tightening torque: 63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)
23. 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)
24. 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.

Installation

Installation is in the reverse order of removal.

Perform the following

1. Adjust a shift cable.
2. Adjust a throttle cable.
3. Refill engine with engine oil.
4. Refill a transaxle with fluid.
5. Refill power steering fluid.
6. Refill a radiator and a reservoir tank with engine coolant.
7. Place a heater control knob on "HOT" position.
8. Bleed air from the cooling system. Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put radiator cap on tightly, then run the engine again and check for leaks.
9. Clean battery posts and cable terminals and assemble.
10. Inspect for fuel leakage. After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.