Engine & Transaxle Assembly - 2.0L: Removal & Installation Kia Soul I рестайлинг

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.

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

1. Remove the engine cover (A). NOTE: To avoid damage, remove the engine cover on room temperature. To avoid damage of the engine cover, do not disengage both front and rear mounting point at the same time.
2. Disconnect the battery terminals (A). The negative terminal first. Tightening torque (+) terminal: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) (-) terminal: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
3. Remove the air cleaner assembly. Remove the air duct (B). Disconnect the breather hose (C). Disconnect the air intake hose and then remove the air cleaner assembly (D). 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: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft) NOTE: Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
4. Disconnect the ECM connectors (A).
5. Remove the ECM (A). Tightening torque Bolts: 19.6 ~ 29.4N.m (2.0 ~ 3.0kgf.m, 14.5 ~ 21.7lb-ft) Nut: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
6. Remove the battery (A).
7. Remove the battery tray (A). Tightening torque: 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
8. Remove the under covers (A). Tightening torque: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
9. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to «COOLANT»(ref-537288-S31244800772013032200000) .
10. Disconnect the radiator upper hose (A).
11. Disconnect the radiator lower hose (A).
12. Recover the refrigerant and then remove the high pressure pipe and the low pressure pipe (A). (Refer to «REFRIGERANT LINE»(ref-537279-S35707227552013032200000) .
13. Disconnect the wiring connectors and harness clamps, and then remove the wiring and protectors from the cylinder head and the intake manifold. The intake OCV (Oil control valve) connector (A) The exhaust OCV (Oil control valve) connector (A) The alternator connector (A) The ignition coil connectors (A) The intake CMPS (Camshaft position sensor) connector (A) The exhaust CMPS (Camshaft position sensor) connector (B) The injector connectors (A) The front and/or rear HO2S (Heated oxygen sensor connectors (A) The condenser connector (A) The PCSV (Purge control solenoid valve) connector (A) The ECTS (Engine coolant temperature sensor) connector (A) The VIS (Variable Intake System) connector (A) The MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (A) The ETC (Electronic throttle control) connector (A) The VCMA (Variable charge motion actuator) connector (A) The CKPS(Crankshaft position sensor) connector (A)
14. Remove the transaxle wire harness connectors, control cable and hoses from the transaxle. (Refer to «AUTOMATIC TRANSAXLE»(ref-537206-S17871285202013032200000) or «MANUAL TRANSAXLE»(ref-537230-S00237316872013032200000) .
15. Disconnect the ATF cooler hoses. (Refer to «REMOVAL»(ref-537303-S36261861692013032200000) .
16. Disconnect the brake booster vacuum hose (A) and the heater hoses (B).
17. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
18. Disconnect the "+" cable (A) and the front connector (B).
19. 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)
20. Remove the steering u-joint mounting bolt (A). (Refer to " «STEERING GEAR BOX»(ref-537243-S29852861412013032200000) ")
21. Remove the front wheels. (Refer to «WHEEL»(ref-537242-S39918692462013032200000) .
22. Remove the lower arms. (Refer to «FRONT LOWER ARM»(ref-537240-S13759532272013032200000) .
23. Remove the stabilizer bar links. (Refer to «FRONT STABILIZER BAR»(ref-537240-S14413349192013032200000) .
24. Remove the tie rod ends (A). (Refer to " «STEERING GEAR BOX»(ref-537243-S29852861412013032200000) ")
25. Disconnect the drive shafts from the axle hubs. (Refer to «REPLACEMENT»(ref-537236-S03170211272013032200000) .
26. 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)
27. 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)
28. Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. 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) CAUTION: After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall down, so support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
29. Disconnect the ground line (A), and then remove the engine mounting support bracket (B). Tightening torque Ground line bolt (A): 10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft) Nut (C): 78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft) Bolt (D) and nuts (E): 58.8 ~ 73.5 N.m (6.0 ~ 7.5 kgf.m, 43.4 ~ 54.2 lb-ft)
30. Disconnect the ground line (A), and then slowly loosen the transaxle mounting bolts (B). Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
31. Lower the engine and transaxle assembly using a floor jack and then remove the engine and transaxle assembly by lifting vehicle.

Removal (2012-02-10~)

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.

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

1. Remove the engine cover (A). NOTE: To avoid damage, remove the engine cover on room temperature. To avoid damage of the engine cover, do not disengage both front and rear mounting point at the same time.
2. Disconnect the battery terminals (A). The negative terminal first. Tightening torque (+) terminal: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) (-) terminal: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
3. Remove the air cleaner assembly. Remove the air duct (B). Disconnect the breather hose (C). Disconnect the air intake hose and then remove the air cleaner assembly (D). 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: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft) NOTE: Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
4. Disconnect the ECM connectors (A).
5. Remove the ECM (A). Tightening torque Bolts: 19.6 ~ 29.4N.m (2.0 ~ 3.0kgf.m, 14.5 ~ 21.7lb-ft) Nut: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
6. Remove the battery (A).
7. Remove the battery tray (A). Tightening torque: 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
8. Remove the under covers (A). Tightening torque: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
9. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to «COOLANT»(ref-537288-S31244800772013032200000) .
10. Disconnect the radiator upper hose (A).
11. Disconnect the radiator lower hose (A).
12. Recover the refrigerant and then remove the high pressure pipe and the low pressure pipe (A). (Refer to «REFRIGERANT LINE»(ref-537279-S35707227552013032200000) .
13. Disconnect the wiring connectors and harness clamps, and then remove the wiring and protectors from the cylinder head and the intake manifold. The intake OCV (Oil control valve) connector (A) The exhaust OCV (Oil control valve) connector (A) The alternator connector (A) The ignition coil connectors (A) The intake CMPS (Camshaft position sensor) connector (A) The exhaust CMPS (Camshaft position sensor) connector (B) The injector connectors (A) The front and/or rear HO2S (Heated oxygen sensor connectors (A) The condenser connector (A) The PCSV (Purge control solenoid valve) connector (A) The ECTS (Engine coolant temperature sensor) connector (A) The VIS (Variable Intake System) connector (A) The MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (A) The ETC (Electronic throttle control) connector (A) The VCMA (Variable charge motion actuator) connector (A) The CKPS(Crankshaft position sensor) connector (A)
14. Remove the transaxle wire harness connectors, control cable and hoses from the transaxle. (Refer to «AUTOMATIC TRANSAXLE»(ref-537206-S17871285202013032200000) or «MANUAL TRANSAXLE»(ref-537230-S00237316872013032200000) .
15. Disconnect the ATF cooler hoses. (Refer to «REMOVAL»(ref-537303-S36261861692013032200000) .
16. Disconnect the brake booster vacuum hose (A) and the heater hoses (B).
17. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
18. Disconnect the "+" cable (A) and the front connector (B).
19. 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)
20. Remove the steering u-joint mounting bolt (A). (Refer to " «STEERING GEAR BOX»(ref-537243-S29852861412013032200000) ")
21. Remove the front wheels. (Refer to «WHEEL»(ref-537242-S39918692462013032200000) .
22. Remove the lower arms. (Refer to «FRONT LOWER ARM»(ref-537240-S13759532272013032200000) .
23. Remove the stabilizer bar links. (Refer to «FRONT STABILIZER BAR»(ref-537240-S14413349192013032200000) .
24. Remove the tie rod ends (A). (Refer to " «STEERING GEAR BOX»(ref-537243-S29852861412013032200000) ")
25. Disconnect the drive shafts from the axle hubs. (Refer to " «FRONT DRIVESHAFT»(ref-537237-S09635589052013032200000) ")
26. 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)
27. 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)
28. Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. 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) CAUTION: After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall down, so support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
29. Disconnect the ground line (A), and then remove the engine mounting support bracket (B). Tightening torque Ground line bolt (A): 10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft) Nuts (C) and bolt (D): 78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)
30. Disconnect the ground line (A), and then slowly loosen the transaxle mounting bolts (B). Tightening torque: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
31. Lower the engine and transaxle assembly using a floor jack and then 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.

Installation

Installation is in the reverse order of removal.

Note. Perform the following: Adjust a shift cable. Refill engine with engine oil. Refill a transaxle with fluid. Refill a radiator and a reservoir tank with engine coolant. Clean battery posts and cable terminals and assemble. Inspect for fuel leakage. After assembling 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. 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.