Kia Sportage: Engine And Transaxle Assembly / Engine And Transaxle Assembly Repair procedures

Kia Sportage QL (2015-2024) Service Manual / Engine Mechanical System / Engine And Transaxle Assembly / Engine And Transaxle Assembly Repair procedures

Removal

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

•	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.

1.	Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")

2.	Remove the air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

3.	Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")

4.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

5.	Drain the engine coolant. (Refer to Cooling System - "Coolant")

6.	Recover the refrigerant and then remove the high pressure pipe and low pressure pipe. (Refer to Heating, Ventilation Air conditioning - "Compressor")

7.	Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to Automatic Transaxle System - "Automatic transaxle")

8.	Disconnect the radiator upper hose (A) and lower hose (B).

9.	Disconnect the ATF cooler hose (A).

10.	Disconnect the vacuum hoses (A).

11.	Disconnect the heater hoses (A).

12.	Disconnect the reservoir hose (A).

13.	Remove the high pressure fuel pump foam (A).

14.	Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).

15.	Disconnect the wiring connectors and harness clamps and remove the wiring protector around the engine and transaxle assembly.

16.	Disconnect the front connector (A).

17.	Disconnect the fuse box wiring cable (A).

18.

Remove the battery wiring protector (B).

Tightening torque :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.7 - 8.6 lb·ft)

19.	Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")

20.

Remove the roll rod bracket (A).

Tightening torque :

Bolts (B):

107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)

Bolts (C):

49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)

Do not reuse the bolt B, which is special bolt coated with bond

21.

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)

22.	Remove the sub frame. (Refer to Suspension system - "Sub frame")

23.	Support the engine and transaxle assembly with a lift table.

24.

Disconnect the engine ground cable (A).

Tightening torque :

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.0 lb·ft)

25.

Remove the engine mounting support bracket (A).

Tightening torque :

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

26.	Disconnect the transaxle ground cable (A).

27.	Disconnect the LH front wheel guard. (Refer to Body (Interior and Exterior) - "Front Wheel Guard")

28.	Remove the transaxle mounting side panel packing (A).

29.

Remove the transaxle mounting bolts (A).

Tightening torque :

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

30.

Remove the engine and transaxle assembly by lifting vehicle (A).

•	Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.

•	When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation

Install the other parts in reverse order of removal.

Perform the following :

•	Adjust a shift cable.

•	Refill engine with engine oil.

•	Refill a transaxle with fluid.

•	Refill power steering fluid.

•	Refill a radiator and a reservoir tank with engine coolant.

•	Place a heater control knob on "HOT" position.

•	Clean battery posts and cable terminals and assemble.

•	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.

•	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.

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