Repair Procedures: Disassembly

Information 

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

1. Remove the engine assembly from the vehicle.

   (Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")

2. Remove the transaxle assembly from the engine assembly.

   (Refer to Automatic Transaxle System - "AUTOMATIC TRANSAXLE ")

3. Install the engine assembly to engine stand for disassembly.
4. Remove the surge tank.

   (Refer to Intake and Exhaust System - "SURGE TANK ")

5. Remove the intake manifold.

   (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

6. Remove the exhaust manifold.

   (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

7. Remove the cylinder head assembly.

   (Refer to Cylinder Head Assembly - "CYLINDER HEAD ")

8. Remove the drive plate and adapter plate.

   (Refer to Cylinder Block - "DRIVE PLATE ")

9. Remove the rear oil seal case.

   (Refer to Cylinder Block - "REAR OIL SEAL ")

10. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

11. Remove the water temperature control assembly.

    (Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")

12. Remove the lower oil pan and upper oil pan.

    (Refer to Lubrication System - "OIL PAN ")

13. Remove the oil pump.

    (Refer to Lubrication System - "OIL PUMP ")

14. Remove the oil filter body.

    (Refer to Lubrication System - "OIL FILTER BODY ")

15. Remove the baffle plate (A).
    Fig 1: Removing Baffle Plate

    Courtesy of KIA MOTORS AMERICA, INC.
16. Check the connecting rod end play.
17. Check the connecting rod cap oil clearance.
18. Detach the piston and connecting rod assemblies from the cylinder block.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod bearing cap.

       Information 

       Mark the connecting rod, and caps to be able to reassemble in the original position and direction.

    3. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

       Information 

       • Keep the bearings, connecting rod and cap together.
       • Arrange the piston and connecting rod assemblies in the correct order.
       • Mark the piston and connecting rod assemblies to be able to reassemble in the original position.
19. Disassemble the piston rings.
    1. Using a piston ring expander, remove the 2 compression rings (A).
    2. Remove the oil ring and coil spring (B) by hand.

       Information 

       Arrange the piston rings in the correct order only.

20. Disassemble the connecting rod from the piston.
    1. Remove the snap ring (C) from the piston.
    2. Using a press, remove the piston pin (D) from the piston.
    3. Disassemble the piston (F) and connecting rod (E).
       Fig 2: Removing Snap Ring From Piston

       Courtesy of KIA MOTORS AMERICA, INC.