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Repair Procedures: Disassembly

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • 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 chain before removing the cylinder head.
  • Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
  • Engine removal is required for this procedure.
  1. Remove the engine assembly from the vehicle. Refer to ENGINE AND TRANSAXLE ASSEMBLY .
  2. Attach the engine to engine stand for disassembly.
  3. Remove the intake manifold and exhaust manifold. Refer to INTAKE AND EXHAUST SYSTEM .
  4. Remove the timing chain. Refer to TIMING SYSTEM .
  5. Remove the water temperature control assembly. Refer to WATER TEMPERATURE CONTROL ASSEMBLY .
  6. Remove the cylinder head. Refer to CYLINDER HEAD .
  7. Remove the oil pump. Refer to LUBRICATION SYSTEM .
  8. Remove the oil filter assembly. Refer to LUBRICATION SYSTEM .
  9. Remove the drive plate (A) and adapter plate (B).
    Fig 1: Drive Plate & Adapter Plate
    G07388710Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the oil cover (A) and gasket (B).
    Fig 2: Oil Cover & Gasket
    G07388711Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the knock sensor (A).
    Fig 3: Knock Sensor
    G07388712Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the upper oil pan (A).
    Fig 4: Upper Oil Pan
    G07388713Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the baffle plate (A).
    Fig 5: Baffle Plate
    G07388714Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the rear oil seal case (A).
    Fig 6: Rear Oil Seal Case
    G07388715Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the oil drain cover (A) and gasket (B).
    Fig 7: Oil Drain Cover & Gasket
    G07388716Courtesy of KIA MOTORS AMERICA, INC.
  16. Check the connecting rod end play.
  17. Check the connecting rod cap oil clearance.
  18. Remove the 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.
  19. Remove the crankshaft main bearing cap and check oil clearance.
  20. Check the crankshaft end play.
  21. Lift the crankshaft (A) out of engine, being careful not to damage journals.
    Fig 8: Crankshaft
    G07388717Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Arrange the main bearings and thrust bearings in the correct order.
  22. Remove the oil jets (A).
    Fig 9: Oil Jets
    G07388718Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the piston rings.
    1. Using a piston ring expander, remove the 2 compression rings.
    2. Remove 2 side rails and the spacer by hand.
      NOTE: Arrange the piston rings in the correct order only.
  24. Disconnect the connecting rod from the piston.

    Remove the snap ring at both ends of piston pin. And push the piston pin to separate and connecting rod.

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