2011 Kia Forte EX

2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

2011 ENGINE

Engine & Transaxle Assembly - Forte/Forte Koup

ENGINE MOUNTING
COMPONENTS AND COMPONENTS LOCATION

Components

Fig. 1: Engine & Transaxle Mounting Brackets, Front & Rear Roll Stopper With Torque Specifications
Courtesy of KIA MOTORS AMERICA, INC.

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 2011 Kia Forte EX
2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

ENGINE AND TRANSAXLE ASSEMBLY

REPAIR PROCEDURES

Removal

CAUTION: l Use fender covers to avoid damaging painted surfaces.

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

NOTE: Mark all wiring and hoses to avoid misconception.

1. Disconnect the battery terminals (A) and remove the battery.

2. Remove the engine cover (B).
3. Disconnect the ECM connector (C).
4. Disconnect the breather hose, and then remove the air duct (D) and the air cleaner assembly (E).

Tightening torque:

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig. 2: Battery Terminals, Engine Cover, ECM Connector & Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.

5. Recover refrigerant and remove the high & low pressure pipe. Refer to REFRIGERANT SYSTEM
SERVICE BASICS .
6. Remove the under covers (A).

Tightening torque:

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

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 2011 Kia Forte EX
2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 3: Under Covers

Courtesy of KIA MOTORS AMERICA, INC.

7. Loosen the drain plug (A), and then drain the engine coolant.

CAUTION: Never remove the radiator cap when the engine is hot. Serious
scalding could be caused by hot fluid under high pressure escaping
from the radiator.

Fig. 4: Radiator Drain Plug

Courtesy of KIA MOTORS AMERICA, INC.

8. Remove the radiator upper hose (A) and lower hose (B).
9. Remove the heater hoses (C).
10. Disconnect the brake booster vacuum hose (D).

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 5: Radiator Upper/Lower, Heater & Brake Booster Vacuum Hoses

Courtesy of KIA MOTORS AMERICA, INC.

11. Disconnect the wiring connectors and harness clamps from the engine.
1. Disconnect the ETC connector (A) and knock sensor connector (B).
2. Disconnect the PCSV connector (C).
3. Disconnect the ECT connector (D).
4. Disconnect the condenser connector (E).
5. Disconnect the CKP sensor connector (F).
6. Disconnect the oxygen sensor connector (G).

Fig. 6: ETC, Knock, PCSV, ECT, CKP & Oxygen Sensor Connectors
Courtesy of KIA MOTORS AMERICA, INC.

7. Disconnect the VCM connector (A) and MAP sensor connector (B). (2.0L SULEV & 2.4 ALL)

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 7: VCM & MAP Sensor Connectors

Courtesy of KIA MOTORS AMERICA, INC.

8. Disconnect the power steering fluid pressure switch connector (A).

9. Disconnect the MAP sensor connector (B).
10. Disconnect the OPS connector (C).
11. Disconnect the alternator connector (D) and 'B' terminal cable from the alternator.
12. Disconnect the A/C switch connector from the compressor.
13. Disconnect the VIS connector.

Fig. 8: Power Steering Fluid Pressure Switch, MAP Sensor, OPS & Alternator Connectors
Courtesy of KIA MOTORS AMERICA, INC.

14. Disconnect the intake OCV connector (A).

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 9: Intake OCV Connector

Courtesy of KIA MOTORS AMERICA, INC.

15. Disconnect the CMP sensor connector (A) and the fuel hose (B).

Fig. 10: CMP Sensor Connector & Fuel Hose

Courtesy of KIA MOTORS AMERICA, INC.

16. Disconnect the injector connectors (A) and the ignition coil connectors (B).

Fig. 11: Injector & Ignition Coil Connectors

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 2011 Kia Forte EX
2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Courtesy of KIA MOTORS AMERICA, INC.

17. Disconnect the starter connector (A), and cable (B) from the starter.

Fig. 12: Starter Cable & Connector

Courtesy of KIA MOTORS AMERICA, INC.

12. Disconnect the transaxle control cable and wiring connectors. Refer to AUTOMATIC TRANSAXLE or
MANUAL TRANSAXLE SYSTEM (M6CF3) - 2.0L or MANUAL TRANSAXLE SYSTEM
(M6GF2) - 2.4L .
13. Remove the lower arm (B) & fork (A) mounting bolt (C). Refer to FRONT LOWER ARM .

Tightening torque:

137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

Fig. 13: Lower Arm, Fork & Mounting Bolts

Courtesy of KIA MOTORS AMERICA, INC.

14. Remove the lower arm ball joint mounting bolts (A). Refer to FRONT LOWER ARM .

Tightening torque:

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

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

Fig. 14: Lower Arm Ball Joint Mounting Bolts

Courtesy of KIA MOTORS AMERICA, INC.

15. Remove the stabilizer bar link mounting nut (A). Refer to FRONT STABILIZER .

Tightening torque:

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

Fig. 15: Stabilizer Bar Link Mounting Nut

Courtesy of KIA MOTORS AMERICA, INC.

16. Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle. Refer to step
6 under REPAIR PROCEDURES .

Tightening torque:

23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 17.4 ~ 24.6lb-ft)

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 16: Tie Rod End

Courtesy of KIA MOTORS AMERICA, INC.

17. Disconnect the driveshaft from the axle hub.

18. Remove power steering return hose (A) and drain power steering fluid.

Fig. 17: Power Steering Return Hose

Courtesy of KIA MOTORS AMERICA, INC.

19. Remove steering u-joint mounting bolt (A). Refer to POWER STEERING GEAR BOX .

Tightening torque:

29.4 ~ 34.3N.m (3.0 ~ 3.5kgf.m, 21.7 ~ 25.3lb-ft)

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 18: Steering U-Joint Mounting Bolt

Courtesy of KIA MOTORS AMERICA, INC.

20. Remove the front muffler (A).

Tightening torque:

39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4 b-ft)

(ULEV)

Fig. 19: Front Muffler (ULEV)

Courtesy of KIA MOTORS AMERICA, INC.

(SULEV)

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 20: Front Muffler (SULEV)

Courtesy of KIA MOTORS AMERICA, INC.

21. Support the sub frame (A) with a floor jack, and then remove the stay (B) and sub frame mounting bolts.

Tightening torque:

137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

Fig. 21: Sub Frame

Courtesy of KIA MOTORS AMERICA, INC.

Tightening torque:

44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 22: Stay

Courtesy of KIA MOTORS AMERICA, INC.

22. Disconnect the ground line and then remove the engine mounting bracket (A).

Tightening torque:

63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Fig. 23: Engine Mounting Bracket

Courtesy of KIA MOTORS AMERICA, INC.

23. Disconnect the ground line and then remove the transaxle mounting bracket (A).

Tightening torque:

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

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

Fig. 24: Transaxle Mounting Bracket

Courtesy of KIA MOTORS AMERICA, INC.

24. Lift up the vehicle and remove the engine and transaxle assembly from the bottom of vehicle.

CAUTION: When removing 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.

Perform the following :

l Adjust a shift cable.

l Adjust a throttle cable.
l Refill engine with engine oil.
l Refill a transaxle with fluid.
l Refill power steering fluid.
l Refill a radiator and a reservoir tank with engine coolant.
l Place a heater control knob on "HOT" position.
l 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.

l Clean battery posts and cable terminals and assemble.

l Inspect for fuel leakage.

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2011 ENGINE Engine & Transaxle Assembly - Forte/Forte Koup

¡ 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.

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