Repair Procedures: Disassembly

NOTE:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

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).

Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")
Remove the transaxle assembly from the engine assembly.
(Refer to Automatic Transaxle System - "AUTOMATIC TRANSAXLE ")
Install the engine assembly to engine stand for disassembly.
Remove the surge tank.
(Refer to Intake and Exhaust System - "SURGE TANK ")
Remove the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Remove the exhaust manifold.
(Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")
Remove the cylinder head assembly.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD ")
Remove the drive plate and adapter plate.
(Refer to Cylinder Block - "DRIVE PLATE ")
Remove the rear oil seal case.
(Refer to Cylinder Block - "REAR OIL SEAL ")
Remove the timing chain.
(Refer to Timing System - "TIMING CHAIN ")
Remove the water temperature control assembly.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Remove the lower oil pan and upper oil pan.
(Refer to Lubrication System - "OIL PAN ")
Remove the oil pump.
(Refer to Lubrication System - "OIL PUMP ")
Remove the oil filter body.
(Refer to Lubrication System - "OIL FILTER BODY ")
Remove the oil cover (A) and gasket (B).

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Remove the water jacket separator.
(Refer to Cylinder Block - "WATER JACKET SEPARATOR ")
Remove the knock sensor (A).

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Remove the upper oil pan.
(Refer to Lubrication System - "OIL PAN ")
Remove the baffle plate (A).

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Check the connecting rod end play.
(Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")
Check the connecting rod cap oil clearance.
(Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")
Remove the crankshaft main bearing cap and check oil clearance.
(Refer to Cylinder Block - "CRANKSHAFT ")
Check the crankshaft end play.
(Refer to Cylinder Block - "CRANKSHAFT ")
Remove the crankshaft.
(Refer to Cylinder Block - "CRANKSHAFT ")
Remove the oil jets (A).

Courtesy of KIA MOTORS AMERICA, INC.