Kia_Sedona_2002-2006

Engine

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove the battery.
  10.  
  11. Remove the engine cover.
  12.  
  13. Remove the air cleaner assembly.
  14.  
  15. Disconnect the engine wiring harness connectors.
  16.  
  17. Disconnect the alternator wiring harness connectors.
  18.  
  19. Disconnect the oil pressure switch connector.
  20.  
  21. Disconnect the oil pressure sensor connector.
  22.  
  23. Disconnect the starter motor wiring harness connectors.
  24.  
  25. Disconnect the transaxle oil cooler hose.
  26.  
  27. Remove the upper and lower radiator hoses.
  28.  
  29. Remove the radiator.
  30.  
  31. Remove the engine ground cable.
  32.  
  33. Disconnect the brake booster vacuum hose.
  34.  
  35. Disconnect the EVAP canister hose.
  36.  
  37. Disconnect the fuel lines.
  38.  
  39. Remove the heater hoses.
  40.  
  41. Disconnect the throttle and cruise control cables.
  42.  
  43. Disconnect the transaxle shift cable.
  44.  
  45. Disconnect the power steering pump hose.
  46.  
  47. Remove the oil pan shield.
  48.  
  49. Remove the exhaust front pipe.
  50.  
  51. Remove the outer tie rod ends.
  52.  
  53. Remove the sway bar links.
  54.  
  55. Remove the lower ball joints.
  56.  
  57. Remove the axle halfshafts.
  58.  
  59. Remove the intermediate shaft bolt.
  60.  
  61. Remove the No. 3 and 4 engine mounts.
  62.  
  63. Support the front subframe with a suitable powertrain jack.
  64.  
  65. Remove the subframe bolts.
  66.  
  67. Remove the impact bar bolts.
  68.  
  69. Lower the powertrain and subframe away from the vehicle.

    Click image to see an enlarged view

    Fig. Engine mount locations and torque specifications-3.5L Engine



    Click image to see an enlarged view

    Fig. Front subframe bolt locations and torque specifications-3.5L Engine

  70.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Subframe bolts: 88-101 ft. lbs. (120-137 Nm)
     
    Impact bar bolts: 69-85 ft. lbs. (93-115 Nm)
     
    Engine mount bolts: 49-69 ft. lbs. (67-93 Nm)
     
    Engine mount through-bolts: 63-86 ft. lbs. (85-117 Nm)
     
    Tie rod ends: 51-58 ft. lbs. (69-79 Nm)
     

  2.  

3.8L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the engine cover. Discharge the air conditioning system. Record the radio anti theft code data. Relieve the fuel system fuel pressure.
  4.  
  5. Disconnect the negative battery terminal. Disconnect the positive battery terminal. Remove the battery from the vehicle.
  6.  
  7. Remove the air intake hose and air cleaner assembly.
  8.  
  9. Disconnect the MAF electrical connector. Disconnect the breather hose from the air cleaner hose. Remove the intake air hose and air cleaner assembly. Remove the battery tray.
  10.  
  11. Remove the radiator grille upper cover. Disconnect the left and right oxygen sensor connectors.
  12.  
  13. Drain the cooling system. Remove the upper and lower radiator hoses. Disconnect and plug the automatic transaxle fluid lines.
  14.  
  15. Disconnect the high and low pressure pipes from the radiator and compressor.
  16.  
  17. Disconnect the engine wiring harness. Remove the engine underhood fuse and relay box. Disconnect the FAM connectors.
  18.  
  19. Unscrew the FAM mounting bolts and remove the FAM from the splash shield.
  20.  
  21. Disconnect the transaxle wire harness connector and remove the transaxle control cable. Disconnect and remove the heater hoses.
  22.  
  23. Remove the brake vacuum hose. Remove the upper power steering hose.
  24.  
  25. Raise and support the vehicle safely. Remove the front tires and wheels.
  26.  
  27. Remove the radiator grille upper cover, for convenience.
  28.  
  29. Disconnect the power steering return hose. Remove the radiator support upper member, for convenience.
    NOTE
    The bottom side bolt, which can be seen after removing the under cover, should be loosened for removal of the radiator support upper member assembly.

  30.  
  31. Remove the under cover. Drain the engine oil. Remove the front exhaust pipe.
  32.  
  33. Disconnect the wheel speed sensor. Disconnect the stabilizer bar link.
  34.  
  35. Remove the brake caliper assemblies. Wire them to the side to prevent damage to the brake hoses.
  36.  
  37. Properly support the engine and transaxle assembly using the proper engine/transaxle support tool.
  38.  
  39. Remove the engine mounting bolt. Remove the transaxle insulator mounting bolt.
  40.  
  41. Support the engine and transaxle assembly with a jack. Remove the sub frame with the engine and transaxle assembly.
  42.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Adjust the shift cable. Fill the engine and transaxle to specification with the proper fluids.
  4.  
  5. Before starting the engine turn the ignition switch to the RUN position so that the fuel pump runs for approximately two seconds and the fuel line pressurizes.
  6.  
  7. Reprogram the radio anti theft code data.
  8.  
  9. Repeat the operation two or three more times, than check for fuel leakage.
  10.