FixVault
Home › Kia › 2010 › Forte EX, Standard › Repair and Diagnosis › Engine Mechanical › Mechanical › Cylinder Block › Cylinder Block › Repair Procedures › Disassembly

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.
  • 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 (2.0L) or ENGINE AND TRANSAXLE ASSEMBLY (2.4L)
  2. Install 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 cylinder head assembly. (Refer to CYLINDER HEAD )
  6. Remove the drive plate (AT only) or fly wheel (MT only).
  7. Remove the oil pump. (Refer to LUBRICATION SYSTEM )
  8. Remove the A/C compressor. (Refer to COMPRESSOR )
  9. Remove the alternator (A).
    Fig 1: Identifying Alternator
    G06494234Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the power steering pump and the bracket. (Refer to POWER STEERING OIL PUMP )
    Fig 2: Identifying Power Steering Pump & Bracket
    G06494235Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the water pump (A) and the water pump gasket.
    Fig 3: Identifying Water Pump
    G06494236Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the tensioner assembly integrated bracket (A).
    Fig 4: Identifying Tensioner Assembly Integrated Bracket
    G06494237Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the oil level gauge (A).
    Fig 5: Identifying Oil Level Gauge
    G06494238Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the knock sensor (A).
    Fig 6: Identifying Knock Sensor
    G06494239Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the oil pressure sensor (A).
    Fig 7: Identifying Oil Pressure Sensor
    G06494240Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the CKP sensor (A).
    Fig 8: Identifying CKP Sensor
    G06494241Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the ladder frame (A).
    Fig 9: Identifying Ladder Frame
    G06494242Courtesy of KIA MOTORS AMERICA, INC.
  18. Check the connecting rod end play.
  19. Remove the connecting rod caps and check oil clearance.
  20. 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.
  21. Remove crankshaft bearing cap and check oil clearance.
  22. Check the crankshaft end play.
  23. Lift the crankshaft (A) out of the engine, being careful not to damage journals.
    NOTE: Arrange the main bearings and thrust bearings in the correct order.
    Fig 10: Identifying Crankshaft
    G06494243Courtesy of KIA MOTORS AMERICA, INC.
  24. 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.

  25. Remove 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.
  26. Disconnect connecting rod from piston.
About FixVault