Kia Forte: Engine And Transmission Assembly / Engine And Transmission Assembly

Kia Forte 2019-2020 (BD) Service Manual / Engine Mechanical System / Engine And Transmission Assembly / Engine And Transmission 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.

Disconnect the battery negative terminal.

2.

Remove the engine cover.

(Refer to Engine and Transaxle Assembly - "Engine Cover")

3.

Remove the air duct and air cleaner assembly.

(Refer to Intake and Exhaust System - "Air Cleaner")

4.

Remove the battery and battery tray.

(Refer to Engine Electrical System - "Battery")

5.

Remove the engine room under cover.

(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

6.

Loosen the drain plug and drain the coolant. Open the radiator cap to make rapid draining.

(Refer to Cooling System - "Coolant")

7.

Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

(Refer to Heating, Ventilation Air conditioning - "Compressor")

8.

Remove the intercooler inlet hose & pipe (A).

Tightening torque

Hose clamp bolt :

4.9 - 6.9 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.1 lb·ft, 43.4 - 60.8 lb·in)

(If equipped with a cap, tighten it until the cap is removed.)

Pipe mounting Bolt :

18.6 - 23.5 N·m (1.9 - 2.4 kgf·m ,13.7 - 17.4 lb·ft)

9.

Disconnect the RCV solenoide valve connector (A) and booster pressure sensor (BPS) connector (B).

10.

Disconnect the intercooler outlet hose (A).

11.

Disconnec the reservoir tank hose (A).

12.

Disconnect the radiator upper hose (A).

13.

Disconnect the radiator lower hose (A).

14.

Disconnect the brake booster vacuum hose (A).

15.

Disconnect the heater hose (A).

16.

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

17.

Remove the engine wiring.

(1)

Disconnect the battery sensor connector (A).

(2)

Disconnect the connector (A) from the fuse box.

(3)

Disconnect the ground cable (B).

Tightening torque:

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

(4)

Remove the main wiring protector (C).

Tightening torque:

6.9 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.1 - 7.2 lb·ft)

(5)

Disconnect the fuse box wiring cable (A).

(6)

Disconnect the battery wiring (B).

18.

Remove the front muffler.

(Refer to Intake and Exhaust System - "Muffler")

19.

Remove the roll rod bracket (A).

Tightening torque

Bolt (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)

20.

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)

21.

Remove the sub frame.

(Refer to Suspension system - "Sub Frame")

22.

Remove the front driveshaft from the front axle.

(Refer to Driveshaft and axle - "Front Driveshaft")

23.

Support the engine and transaxle assembly with a lift table.

24.

Remove the engine mounting support bracket (A).

Tightening torque

Nut (B) :

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

Bolt and Nuts (C) :

58.8 - 73.5 N·m (6.0 - 7.5 kgf·m, 43.4 - 54.2 lb·ft)

25.

Disconnect the engine ground cable (A).

26.

Remove the transaxle mounting side pannel packing (A).

27.

.Remove the transaxle support bracket mounting bolt (A).

Tightening torque :

98.1 - 117.7 N·m (10.0 - 12.0 kgf·m, 72.3 - 86.8 lb·ft)

28.

Disconnect the transaxle ground cable (A).

29.

Remove the engine and transaxle assembly by lifting vehicle.

  

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
1.

Installation is in the reverse order of removal.

2.

Refill with the engine oil.

(Refer to Lubrication System - "Engine Oil")

3.

Refill the radiator with coolant.

(Refer to Cooling System - "Coolant")

Perform the following

• Adjust shift cable

• Refill transaxle with transaxle fluid.

• 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.

• Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.

Engine Mounting
Components and components location Components 1. Engine mounting bracket 2. Engine mounting support bracket 3. Roll rod bracket 4. Transaxle mounting brac ...

Intake And Exhaust System
...

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