Kia Sorento 2003-05

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the battery and air cleaner assembly.
  4.  
  5. Remove the hood from the vehicle.
  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the transmission fluid.
  12.  
  13. Relieve fuel system pressure.
  14.  
  15. Remove the upper and lower radiator hoses.
  16.  
  17. Remove the heater hoses.
  18.  
  19. Remove the radiator.
  20.  
  21. Remove the breather hose and air-intake hose.
  22.  
  23. Disconnect the throttle and cruise control cables.
  24.  
  25. Disconnect the oil pressure switch connector.
  26.  
  27. Disconnect the oil pressure sensor connector.
  28.  
  29. Remove the engine ground cable.
  30.  
  31. Disconnect the EVAP canister hose.
  32.  
  33. Disconnect the brake booster vacuum hose.
  34.  
  35. Disconnect the fuel lines.
  36.  
  37. Remove the accessory drive belts.
  38.  
  39. Disconnect the power steering hoses from the pump.
  40.  
  41. Disconnect the alternator wiring harness connectors.
  42.  
  43. If equipped with an automatic transmission, disconnect the oil cooler lines.
  44.  
  45. Disconnect the starter motor wiring harness connectors.
  46.  
  47. Remove the starter motor.
  48.  
  49. Remove the exhaust front pipes from the exhaust manifolds.
  50.  
  51. Disconnect the transmission shift cable or clutch cable, if equipped.
  52.  
  53. Remove the halfshafts.
  54.  
  55. Support the transmission with a jack.
  56.  
  57. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.
  58.  
  59. Remove the transmission from the cross member.
  60.  
  61. Remove the cross member.
  62.  
  63. Remove the drive shaft.
  64.  
  65. Remove the engine mounting bolts and remove the engine assembly.
  66.  


    Click image to see an enlarged view

    Fig. Engine mount locations and torque specifications


To install:

  1. Installation is the reverse of removal but please note the following steps:

    Tighten the transaxle mounting bracket bolts to 15-21 ft. lbs. (20-28 Nm)
     
    Tighten the engine mount bracket bolts to 51-65 ft. lbs. (69-88 Nm)
     

  2.  
  3. Make sure all cable, harness connectors and hoses are properly connected to the engine and transmission.
  4.  
  5. Fill the engine crankcase to the correct level.
  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Fill the power steering system.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Check the wheel alignment and adjust as necessary.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery and air cleaner assembly.
  4.  
  5. Remove the hood from the vehicle.
  6.  
  7. Drain the cooling system. Properly discharge the air conditioning system, as required.
  8.  
  9. Drain the engine oil.
  10.  
  11. Drain the transmission fluid.
  12.  
  13. Relieve fuel system pressure.
  14.  
  15. Remove the upper and lower radiator hoses.
  16.  
  17. Remove the heater hoses.
  18.  
  19. Remove the radiator.
  20.  
  21. Remove the breather hose and air-intake hose.
  22.  
  23. Disconnect the throttle and cruise control cables.
  24.  
  25. Disconnect the oil pressure switch connector.
  26.  
  27. Disconnect the oil pressure sensor connector.
  28.  
  29. Remove the engine ground cable.
  30.  
  31. Disconnect the EVAP canister hose.
  32.  
  33. Disconnect the brake booster vacuum hose.
  34.  
  35. Disconnect the fuel lines.
  36.  
  37. Remove the accessory drive belts.
  38.  
  39. Disconnect the power steering hoses from the pump.
  40.  
  41. Disconnect the alternator wiring harness connectors.
  42.  
  43. If equipped with an automatic transmission, disconnect the oil cooler lines.
  44.  
  45. Disconnect the starter motor wiring harness connectors.
  46.  
  47. Remove the starter motor.
  48.  
  49. Remove the exhaust front pipes from the exhaust manifolds.
  50.  
  51. Disconnect the transmission shift cable or clutch cable, if equipped.
  52.  
  53. Remove the halfshafts.
  54.  
  55. Support the transmission with a jack.
  56.  
  57. Make sure all cable, harness connectors and hoses are disconnected from the engine and transmission.
  58.  
  59. Remove the transmission from the crossmember.
  60.  
  61. Remove the crossmember.
  62.  
  63. Remove the driveshaft.
  64.  
  65. Remove the engine mounting bolts and remove the engine assembly.

    Click image to see an enlarged view

    Fig. Engine mount locations and torque specifications

  66.  

To install:

  1. Installation is the reverse of removal but please note the following steps:

    Tighten the transaxle mounting bracket bolts to 15-21 ft. lbs. (20-28 Nm)
     
    Tighten the engine mount bracket bolts to 51-65 ft. lbs. (69-88 Nm)
     

  2.  
  3. Make sure all cable, harness connectors and hoses are properly connected to the engine and transmission.
  4.  
  5. Fill the engine crankcase to the correct level.
  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Fill the cooling system.
  10.  
  11. Fill the power steering system.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Check the wheel alignment and adjust as necessary.
  16.  

 
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