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Repair Procedures: Removal

CAUTION: When removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there is possible risk of injury from leakage of high pressure fuel. Therefore, do not attempt repairing immediately after the engine stops.
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.

  1. Remove the engine cover.

    (Refer to Engine And Transaxle Assembly - "ENGINE COVER ")

  2. Remove the engine room front under cover and engine room RH side cover.

    (Refer to Engine And Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  3. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  4. Drain the engine oil.

    (Refer to Lubrication System - "ENGINE OIL ")

  5. Remove the air cleaner assembly.

    (Refer to Intake And Exhaust System - "AIR CLEANER ")

  6. Disconnect the variable force solenoid (VFS) valve connector (A) and ground cable (B).
    Fig 1: Locating Variable Force Solenoid Valve Connector & Ground Cable
    G12290363Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the surge tank.

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

  8. Remove the intake manifold.

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

  9. Remove the LH/RH cylinder head cover.

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

  10. Remove the drive belt.

    (Refer to Drive Belt System - "DRIVE BELT ")

  11. Remove the idler.

    (Refer to Drive Belt System - "IDLER ")

  12. Remove the drive belt tensioner.

    (Refer to Drive Belt System - "DRIVE BELT TENSIONER ")

  13. Remove the crankshaft damper pulley.

    (Refer to Drive Belt System - "CRANKSHAFT DAMPER PULLEY ")

  14. Remove the water pump.

    (Refer to Cooling System - "WATER PUMP ")

  15. Remove the lower oil pan.

    (Refer to Lubrication System - "OIL PAN ")

  16. Remove the RH and LH variable force solenoid (VFS) valve (A).

    [RH] 

    Fig 2: Locating RH Variable Force Solenoid (VFS) Valve With Bolts
    G12290364Courtesy of KIA MOTORS AMERICA, INC.

    [LH] 

    Fig 3: Locating LH Variable Force Solenoid (VFS) Valve With Bolts
    G12290365Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: The variable force solenoid (VFS) must be removed before removing the timing chain cover.
  17. Remove the engine mounting bracket.
    1. Install the jack to the edge of the upper oil pan to support the engine.
      NOTE: Insert a rubber block between jack and upper oil pan.
    2. Disconnect the engine ground cable (A).
      Fig 4: Locating Engine Ground Cable
      G12290366Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the engine mounting support bracket (A).
    Fig 5: Locating Engine Mounting Support Bracket With Nuts
    G12290367Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the timing chain cover (A).
    Fig 6: Locating Timing Chain Cover With Bolts
    G12290368Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
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