Cylinder Head Assembly: Removal

NOTE: Engine removal is not required for this procedure.

CAUTION:

Use Fender cover to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:

Mark all wiring and hoses to avoid misconnection.
Inspect the timing belt before removing the cylinder head.
Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

Disconnect the terminals (A) from battery and remove the heat shield (B).

Fig 1: Disconnecting Battery Terminals
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine cover.

Fig 2: Removing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Drain the engine coolant (remove radiator cap to speed draining).
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 3: Removing AFS & Intake Air Hose
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the air cleaner element.
5. Remove the bolts (B) and air cleaner lower cover (A).
  
  Fig 4: Removing Air Cleaner Lower Cover
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the upper radiator hose (A) and lower radiator hose (B).

Fig 5: Removing Upper & Lower Radiator Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater hoses (A).

Fig 6: Removing Heater Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Remove the accelerator cable (A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.

Fig 7: Removing Accelerator Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
1. Disconnect the OCV (Oil Control Valve) connector (A).
2. Disconnect the oil temperature sensor connector (B).
3. Disconnect the ECT (Engine Coolant Temperature) sensor connector (C).
4. Disconnect the ignition coil connector (D).
  
  Fig 8: Disconnecting Engine Sensors
  Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the TPS (Throttle Position Sensor) connector (A).
6. Disconnect the ISA (Idle Speed Actuator) connector (B).
  
  Fig 9: Disconnecting TPS & ISA Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the CMP (Camshaft Position Sensor) connector (A).
8. Disconnect the four injector connectors (B).
9. Disconnect the knock sensor connector (C).
10. Disconnect the ground cables (D, E) from the intake manifold and vehicle's body.
11. Disconnect the air conditioner compressor switch connector (F).
  
  Fig 10: Disconnecting Engine Sensor Connectors & Ground Cables
  Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the front heated oxygen sensor connector (A).
13. Disconnect the CKP (Crankshaft Position Sensor) connector (B).
14. Disconnect the oil pressure switch connector (C).
  
  Fig 11: Disconnecting Oil Pressure Switch Connector
  Courtesy of KIA MOTORS AMERICA, INC.
15. Disconnect the PCSV (Purge Control Solenoid Valve) connector (A).
  
  Fig 12: Disconnecting the PCSV
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel inlet hose (A) of the delivery pipe side.
Disconnect the hose (B) of the PCSV (Purge Control Solenoid Valve) side.
Remove the brake booster vacuum hose (C).

Fig 13: Disconnecting Fuel & Vacuum Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Remove the power steering pump drive belt.
Remove the power steering pump and fix the pump to vehicle with a wire.
Remove the bolts (B, C) and power steering pump bracket (A).

Fig 14: Removing Power Steering Pump & Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the spark plug cables.

Fig 15: Removing Spark Plug Cables
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust manifold. See EXHAUST MANIFOLD .
Remove the intake manifold. See INTAKE MANIFOLD .
Remove the timing belt. See TIMING BELT .
Remove the PCV (Positive Crankcase Ventilation) hose.
Remove the cylinder head cover. See TIMING BELT .
Remove the camshaft sprocket. See TIMING BELT .
Insert a stopper pin or other device into timing chain auto tensioner and remove the auto tensioner.

Fig 16: Removing Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the camshaft bearing caps (A) and camshafts (B).

Fig 17: Removing Camshaft Bearing Caps
Courtesy of KIA MOTORS AMERICA, INC.
Remove the OCV (Oil Control Valve) (A).

Fig 18: Removing Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
Remove the OCV (Oil Control Valve) filter (A).

Fig 19: Removing Oil Control Valve Filter
Courtesy of KIA MOTORS AMERICA, INC.
Remove the water hose (A) from water pipe (B).

Fig 20: Removing Water Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cylinder head bolts, then remove the cylinder head.
1. Using 8 mm and 10 mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown in illustration. Remove the 10 cylinder head bolts and plate washers.
2. Lift the cylinder head from the dowels on the cylinder block and place 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.