Kia Rio: Removal
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Use fender covers to avoid damaging painted surfaces.
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To avoid damage, unplug the wiring connectors carefully
while holding the connector portion.
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Mark all wiring and hoses to avoid misconnection.
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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).
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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)
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3. |
Remove the air cleaner assembly.
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(1) |
Remove the air duct (A).
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(2) |
Disconnect the breather hose (B).
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(3) |
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)
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Install the air intake hose while the plate of
the hose clamp must be in line with the stopper of the
hose.
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Install the air intake hose while the groove of
hose must be matched to the protrusion of the throttle
body.
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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)
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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)
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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)
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7. |
Loosen the drain plug, and drain the engine coolant. Remove the
radiator cap to drain with speed. (Refer to Cooling system in this group)
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8. |
Disconnect the radiator upper hose (A) and lower hose (B).
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Install the radiator hoses as shown illustrations.
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9. |
Recover the refrigerant and then remove the high pressure pipe
and low pressure pipe (A). (Refer to Air conditioning system in HA Group.)
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10. |
Disconnect the (+) cable (A) from the fuse/relay box.
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11. |
Disconnect the wiring connectors and harness clamps, and remove
the wiring and protectors from the cylinder head and intake manifold.
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(1) |
The A/C compressor switch connector (A) and the alternator
connector (B)
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(2) |
The intake OCV (Oil control valve) connector (A) and the
exhaust OCV (Oil control valve) connector (B)
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(3) |
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)
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(4) |
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)
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(5) |
The oxygen sensor connectors (A) and the condenser connector
(B)
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(6) |
The ECTS (Engine coolant temperature sensor) connector
(A) and the ground line (B)
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(7) |
The ETC (Electronic throttle control) connector (A) and
the MAPS (Manifold absolute pressure sensor) & IATS (Intake
air temperature sensor) connector (B)
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(8) |
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)
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12. |
Remove the transaxle wire harness connectors and control cable
from the transaxle. (Refer to AT or MT group).
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13. |
Disconnect the fuel hose (A) and the PCSV (Purge control solenoid
valve) hose (B).
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14. |
Disconnect the brake booster vacuum hose (A) and the heater hose
(B).
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Install the heater hoses as shown illustrations.
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15. |
Disconnect the ATF cooler hoses (A). (Refer to AT group)
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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)
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17. |
Remove the steering u-joint mounting bolt (A). (Refer to ST group)
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18. |
Remove the front wheels. (Refer to SS group)
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19. |
Remove the lower arms (A). (Refer to SS group)
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20. |
Remove the stabilizer bar links (A). (Refer to SS group)
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21. |
Remove the tie rod ends (A). (Refer to ST group)
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22. |
Disconnect the drive shafts from the axle hubs. (Refer to DS group)
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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)
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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)
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25. |
Support the sub frame (A) with a floor jack, and then remove the
sub frame mounting bolts and nuts. (Refer to SS group)
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)
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After removing the sub frame mounting bolts and
nuts, the engine and transaxle assembly may fall downward.
Securely support the assemblies with floor jack.
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Verify that the hoses and connectors are disconnected
before removing the engine and transaxle assembly.
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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)
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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)
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28. |
Remove the engine and transaxle assembly (A) by lifting vehicle.
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When removing the engine and transaxle assembly, be careful
not to damage any surrounding parts or body components.
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1. Transaxle mounting bracket
2. Roll rod bracket
3. Engine mounting bracket
4. Engine mounting support bracket
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Installation is in the reverse order of removal.
Perform the following :
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Adjust a shift cable.
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Refill engine with engine oil.
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Components
Installation