Kia Picanto JA: Engine And Transaxle Assembly / Engine And Transaxle Assembly

Kia Picanto (JA) 2017-{YEAR} Service & Repair 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.
•
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.
1.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
2.
Remove the engine room under cover and side cover.
(Refer to Engine and Transaxle Assembly - Engine Room Under Cover")
3.
Drain the coolant.
(Refer to Cooling System - "Coolant")
4.
Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
(Refer to Heating, Ventilation Air conditioning - "Compressor")
5.
Remove the battery and battery tray.
(Refer to Engine Electrical System - "Battery")
6.
Remove the intercooler inlet hoses & 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)
(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)

7.
Disconnect the intercooler outlet hose & pipe (A)
Tightening torque :
4.9 - 6.9 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.1 lb·ft)
(If equipped with a cap, tighten it until the cap is removed.)

8.
Disconnect the water return hose (A) and turbo charger water drain hose (B).

9.
Disconnect the radiator upper hose (A).

10.
Disconnect the radiator lower hose (A).

11.
Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).

12.
Disconnect the brake booster vacuum hose (A).

13.
Disconnect the recirculation valve (RCV) hose (A) and vacuum hose (B).

14.
Disconnect the heater hoses (A).

15.
Disconnect the wiring connectors and harness clamps and remove the connector brackets around the engine and transaxle.

16.
Disconnect the fuse box wiring cable (A).

17.
Remove the transaxle wire harness connectors and control cable from the transaxle.
(Refer to Manual Transaxle System - "Manual transaxle")
18.
Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
19.
Remove the roll rod bracket (A).
Tightening torque
Bolt (B) : 127.5 - 147.1 N·m (13.0 - 15.0 kgf·m, 94.0 - 108.5 lb·ft)
Bolt (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.
Support the engine and transaxle assembly with a lift table.
23.
Remove the engine mounting bracket (A).
Tightening torque :
49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 lb·ft)

24.
Disconnect the transaxle ground cable (A).

25.
Remove the transaxle side panel packing (A).

26.
Remove the transaxle mounting bolts (A).
Tightening torque :
88.2 - 107.8 N·m (9.0 - 11.0 kgf·m, 65.1 - 79.5 lb·ft)

27.
Remove the engine and transaxle assembly (A) by lifting vehicle.

   
•
Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
•
When remove the engine and transaxle assembly, be careful not to damage any surroundings parts or body components.
Installation
Install in the reverse order of removal.
Perform the followings :
•
Refill engine with engine oil.
•
Refill transaxle with fluid.
•
Refill radiator and reservoir tank with engine coolant.
•
Clean battery posts and cable terminals with sandpaper. Then, assemble them and apply grease to prevent corrosion.
•
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.
•
Switch heater control knob to "HOT" position.
•
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, and add coolant if needed.
This will allow trapped air to be released from the cooling system.
–
Put radiator cap on tightly, then run the engine again and check for leaks.

    Engine Mounting

    Components and components location Components 1. Engine mounting bracket 2. Roll rod bracket 3. Transaxle mounting bracket Repair procedures Removal and Installation Engine Mounting Bracket 1...

    Intake And Exhaust System

    ..

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