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Repair Procedures: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. M/T: remove flywheel.
  2. A/T: remove drive plate.
  3. Install engine to engine stand for disassembly.
  4. Remove timing belt. (Refer to TIMING SYSTEM - 2.0L )
  5. Remove cylinder head. (Refer to CYLINDER HEAD ASSEMBLY - 2.0L )
  6. Remove oil level gauge assembly (A).
    Fig 1: Identifying Oil Level Gauge Assembly
    G06523316Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove knock sensor.
  8. Remove oil pressure sensor (A).
    Fig 2: Identifying Oil Pressure Sensor
    G06523317Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove water pump.
  10. Remove oil pan.
  11. Remove oil screen.

    Remove the 2 bolts (C), oil screen (A) and gasket (B).

    Fig 3: Identifying Oil Screen, Gasket, & Bolts
    G06523318Courtesy of KIA MOTORS AMERICA, INC.
  12. Check the connecting rod end play.
  13. Remove the connecting rod caps and check oil clearance.
  14. Remove piston and connecting rod assemblies.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
    NOTE:
    • Keep the bearings, connecting rod, and cap together.
    • Arrange the piston and connecting rod assemblies in the correct order.
  15. Remove front case.
  16. Remove rear oil seal case.

    Remove the 5 bolts (B) and rear oil seal case (A).

    Fig 4: Identifying Rear Oil Seal Case & Bolts
    G06523319Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove crankshaft bearing cap and check oil clearance.
  18. Check the crankshaft end play.
  19. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    NOTE: Arrange the main bearings and thrust washers in the correct order.
    Fig 5: Identifying Crankshaft
    G06523320Courtesy of KIA MOTORS AMERICA, INC.
  20. Check fit between piston and piston pin.

    Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

  21. Remove piston rings.
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove the 2 side rails and oil ring by hand.
    NOTE: Arrange the piston rings in the correct order only.
  22. Disconnect connecting rod from piston.
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