Repair Procedures: Disassembly

NOTE:

Use fender covers to avoid damaging painted surfaces.
To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) 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.

Information

Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).

Remove the engine assembly from the vehicle.
(Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")
Remove the manual tranaxle assembly from the engine assembly.
Remove the intelligent variable transmission assembly from the engine assembly.

(Refer to Intelligent Variable Transmission (IVT) System - "REPAIR PROCEDURES ")
Intelligent variable transmission: Remove the drive plate
(Refer to Cylinder Block - "DRIVE PLATE ")

Manual transaxle: Remove the flywheel.

(Refer to Cylinder Block - "FLYWHEEL ")
Remove the rear oil seal.
(Refer to Cylinder Block - "REAR OIL SEAL ")
Install the engine to engine stand for disassembly.
Remove the timing chain.
(Refer to Timing System - "TIMING CHAIN ")
Remove the water pump assembly.
(Refer to Cooling System - "WATER PUMP ")
Remove the thermostat
(Refer to Cooling System - "THERMOSTAT ")
Remove the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Remove the A/C compressor.
(Refer to Heating, Ventilation Air conditioning - "COMPRESSOR ")
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 oil filter.
(Refer to Lubrication System - "ENGINE OIL ")
Remove the oil screen.
(Refer to Lubrication System - "OIL PAN ")
Remove the piston and connecting rod assemblies.
(Refer to Cylinder Block - "PISTON AND CONNECTING ROD ")
Remove the crankshaft.
(Refer to Cylinder Block - "CRANKSHAFT ")
Remove the knock sensor.
(Refer to Engine Control/Fuel System - "KNOCK SENSOR (KS) ")
Remove the crankshaft position sensor (CKPS).
(Refer to Engine Control/Fuel System - "CRANKSHAFT POSITION SENSOR (CKPS) ")
Remove the oil pressure switch.
(Refer to Lubrication System - "OIL PRESSURE SWITCH ")
Remove the piston cooling jet (A).
Tightening torque:

8.8 - 12.7 N.m (0.9 - 1.3 kgf.m, 6.5 - 9.4 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.