Engine & Transaxle Assembly: Removal & Installation Kia Rio III

Removal

Note. Mark all wiring and hoses to avoid misconnection. To release the fuel system pressure before removing the engine assembly, start the engine with the fuel pump relay removed. And then turn off the ignition switch after engine stops.

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1. Remove the engine cover (A).
2. Disconnect the battery terminals (A). Disconnect the negative terminal first. Tightening torque (+) terminal: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) (-) terminal (without battery sensor): 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) (-) terminal (with battery sensor): 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
3. Remove the air cleaner assembly. Remove the air duct (A). Disconnect the breather hose (B). Disconnect the air intake hose (C) and then remove the air cleaner assembly (D). Tightening torque Hose clamp bolt: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft) Air cleaner assembly bolts: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft) NOTE: Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose. Install the air intake hose while the groove of hose must be matched to the protrusion of the throttle body.
4. Remove the battery (A) after removing the mounting bracket. Tightening torque: 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
5. Disconnect the ECM connectors (A) and then remove the ECM (B) and the battery tray (C). Tightening torque ECM bracket bolts&nut: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft) Battery tray bolts: 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
6. Remove the under cover (A). Tightening torque: 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
7. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to «COOLING SYSTEM»(ref-536074) in this group)
8. Disconnect the radiator upper hose (A) and lower hose (B). NOTE: Install the radiator hoses as shown illustrations.
9. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe (A). (Refer to «AIR CONDITIONING SYSTEM»(ref-536075) in HA Group.)
10. Disconnect the (+) cable (A) from the fuse/relay box.
11. Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold. The A/C compressor switch connector (A) and the alternator connector (B) The intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B) The ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D) The FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C) The oxygen sensor connectors (A) and the condenser connector (B) The ECTS (Engine coolant temperature sensor) connector (A) and the ground line (B) The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor)&IATS (Intake air temperature sensor) connector (B) The knock sensor connector (A), the CKPS (Crankshaft position sensor) connector (B), the front connector (C), the starter connector (D) and the oil pressure connector (E)
12. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to «REMOVAL»(ref-536105-S09659304162013031400000) .
13. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
14. Disconnect the brake booster vacuum hose (A) and the heater hose (B). NOTE: Install the heater hoses as shown illustrations.
15. Disconnect the ATF cooler hoses (A). (Refer to «REMOVAL»(ref-536105-S09659304162013031400000) .
16. Remove the front muffler (A) after removing the rear oxygen sensor connector from the bracket. Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
17. Remove the steering u-joint mounting bolt (A). (Refer to «STEERING COLUMN AND SHAFT»(ref-536086-S11460282932013031400000) .
18. Remove the front wheels. (Refer to «WHEEL»(ref-536116-S11187265452013031400000) .
19. Remove the lower arms (A). (Refer to «FRONT LOWER ARM»(ref-536114-S02103356962013031400000) .
20. Remove the stabilizer bar links (A). (Refer to «FRONT STABILIZER LINK»(ref-536114-S12046513672013031400000) .
21. Remove the tie rod ends (A). .
22. Disconnect the drive shafts from the axle hubs. (Refer to «FRONT AXLE ASSEMBLY»(ref-536110) .
23. Remove the roll rod bracket (A). Tightening torque Nut (B): 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft) Bolt (C): 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
24. 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)
25. Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. (Refer to «SUB FRAME»(ref-536114-S32991843642013031400000) . Tightening torque Sub frame mounting bolts&nuts: 156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft) Sub frame stay mounting bolts: 44.1 ~ 53.9 N.m (4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft) NOTE: After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall downward. Securely support the assemblies with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
26. Disconnect the ground line (A) and then remove the engine mounting support bracket (B). Tightening torque Ground line bolt: 10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft) Nut (C): 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft) Bolt (D) and nuts (E): 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
27. Disconnect the ground line (A), and then remove the transaxle mounting bracket bolts (B). Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
28. Remove the engine and transaxle assembly (A) by lifting 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. Refill engine with engine oil.
3. Refill a transaxle with fluid.
4. Refill power steering fluid.
5. Refill a radiator and a reservoir tank with engine coolant.
6. Clean battery posts and cable terminals and assemble.
7. 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.

1. 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.