Kia Niro: Engine And Transaxle Assembly / Engine And Transaxle Assembly Repair procedures

Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.

Be sure to shut off the high voltage circuit according to the “High Voltage Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.

Use fender covers to avoid damaging painted surfaces.

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

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.

Tightening torque :

3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft)

Disconnect the ground cable (A).

Disconnect the fuse box main wiring connector (B).

Pull the main wiring protector (C) upward to remove it from engine room.

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)

Tightening torque :

49.0 - 68.6 N·m (5.0 - 7.0 kgf·m, 36.2 - 50.6 lb·ft)

Tightening torque :

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

Tightening torque

Nut (B) :

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

Bolt (C) and nuts (D) :

58.8 - 73.5 N·m (6.0 - 7.5 kgf·m, 43.3 - 54.2 lb·ft)

Do not reuse the bolt C, which is special bolt coated with bond.

Tightening torque :

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

Tightening torque :

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

Adjust a shift cable.

Refill engine with engine oil.

Refill a transaxle with fluid.

Refill an engine radiator and a reservoir tank with coolant.

Refill an inverter radiator and a reservoir tank with coolant.

Clean battery posts and cable terminals and assemble.

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.

Bleed air from the hybrid motor cooling system. (Refer to Hybrid Motor System - "Coolant")

Bleed air from the engine 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.