Cylinder Head Assembly: Removal

Engine removal is not required for this procedure.

1. Disconnect the terminals (A) from battery and remove the battery.
   Fig 1: Identifying Battery Terminals

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2. Remove the engine cover (A).
   Fig 2: Identifying Engine Cover

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3. Remove the under cover (A).
   Fig 3: Identifying Under Cover

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4. Drain the engine coolant. (Refer to ENGINE COOLANT REFILLING AND BLEEDING  ) Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly.
   1. Disconnect the AFS (Air Flow Sensor) connector (A).
   2. Disconnect the breather hose (B) from intake air hose (D).
   3. Remove the intake air hose (D) and air cleaner upper cover (C).
      Fig 4: Identifying Intake Air Hose And Air Cleaner Upper Cover

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   4. Disconnect the ECM connector (A) and ECM connector (B) (A/T only).
   5. Remove the air cleaner element and air cleaner lower cover (C).
      Fig 5: Identifying Air Cleaner Element And Air Cleaner Lower Cover

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6. Remove the battery tray (A).
   Fig 6: Identifying Battery Tray

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7. Remove the upper radiator hose (A) and lower radiator hose (B).
   Fig 7: Identifying Upper Radiator Hose And Lower Radiator Hose

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8. Remove the heater hoses (A).
9. Remove the fuel hose (B).
   Fig 8: Identifying Fuel Hose

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10. Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
11. Disconnect the TPS (Throttle Position Sensor) connector (B).
    Fig 9: Identifying Throttle Position Sensor Connector

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12. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
    1. Disconnect the rear oxygen sensor connector (A).
    2. Disconnect the air conditioner compressor switch connector (B).
    3. Disconnect the knock sensor connector (C).
    4. Disconnect the injector connectors (No.3,4) (D).
    5. Disconnect the injector connectors (No.1,2) (E)
       Fig 10: Identifying Injector Connectors

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    6. Remove the wire harness bracket (A).
    7. Disconnect the ISA (Idle Speed Actuator) connector (B).
       Fig 11: Identifying Idle Speed Actuator Connector

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    8. Disconnect the front oxygen sensor connector (A).
    9. Disconnect the CKP (Crankshaft Position Sensor) connector (B).
    10. Disconnect the OCV (Oil Control Valve) connector (C).
        Fig 12: Identifying Oil Control Valve Connector

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    11. Disconnect the ignition coil connector (A).
    12. Disconnect the ignition coil condenser connector (A).
    13. Disconnect the CMP (Camshaft Position Sensor) connector (C).
    14. Disconnect the ground cable (D).
    15. Remove the wire harness bracket (E).
        • 1.6 CVVT 
          Fig 13: Identifying Wire Harness Bracket

          Courtesy of KIA MOTORS AMERICA, INC.
13. Disconnect the hose (A) of the PCSV (Purge Control Solenoid Valve) side.
14. Remove the brake booster vacuum hose (B).
    Fig 14: Identifying Brake Booster Vacuum Hose

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15. Remove the power steering pump and fix the pump to vehicle with a wire. (Refer to MECHANICAL POWER STEERING SYSTEM )
16. Remove the ignition coil. (Refer to ENGINE ELECTRICAL SYSTEM - IGNITION SYSTEM )
17. Remove the exhaust manifold. (Refer to REMOVAL  )
18. Remove the intake manifold. (Refer to REMOVAL  )
19. Remove the timing belt. (Refer to REMOVAL  )
20. Remove the cylinder head cover. (Refer to REMOVAL  )
21. Remove the camshaft sprocket. (Refer to REMOVAL  )
22. Remove the timing chain auto tensioner (A).
    • 1.6 CVVT 
      Fig 15: Identifying Timing Chain Auto Tensioner

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23. Remove the camshaft bearing caps (A) and camshafts (B).
    • 1.6 CVVT 
      Fig 16: Identifying Camshaft Bearing Caps And Camshafts

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24. Remove the OCV (Oil Control Valve) (A).
    • 1.6 CVVT 
      Fig 17: Identifying Oil Control Valve

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25. Remove the OCV (Oil Control Valve) filter (A).
    • 1.6 CVVT 
      Fig 18: Identifying Oil Control Valve Filter

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26. Remove the engine mounting support bracket fixing bolts (A).
    Fig 19: Identifying Engine Mounting Support Bracket Fixing Bolts

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27. Remove the cylinder head bolts, then remove the cylinder head.
    1. Using 8mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
       • 1.6 CVVT 
         Fig 20: Identifying Loosening Sequence Of Cylinder Head Bolts

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       CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.
    2. Lift the cylinder head from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench.
       CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.