Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

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.

WARNING: In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

Disconnect the battery negative terminal (A).
Remove the engine cover (B) and the air duct (C).

Fig 1: Battery Negative Terminal, Engine Cover & Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A), the brake booster vacuum hose (B) and the intensifier hose (C).
2. Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
  
  Fig 2: Air Cleaner Assembly, Breather, Brake Booster Vacuum, Intensifier & Air Intake Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  - Install the air intake hose match groove to throttle body groove.
    
    Fig 3: Identifying Air Intake Hose & Throttle Body Grooves
    Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH front wheel.
Remove the under covers (A, B).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 4: Under Covers
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.
Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No. 1 cylinder to the top dead center on compression stroke.

Fig 5: Identifying Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the exhaust OCV (Oil control valve) connector (A).

Fig 6: Exhaust OCV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ignition coil connectors (A) and the fuel pump connector (B), then remove the wiring protector (C).

Fig 7: Ignition Coil Connectors, Fuel Pump Connector & Wiring Protector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ignition coils (A).

Fig 8: Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

Fig 9: Fuel Hose & PCSV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect PCSV (Purge control solenoid valve) connector (A) and loosen the vacuum & PCSV (Purge control solenoid valve) pipe assembly mounting bolts and nut.

Fig 10: PCSV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure pipe (A). Refer to HIGH PRESSURE FUEL PUMP .

Fig 11: High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pump (A) and the roller tappet (B). Refer to HIGH PRESSURE FUEL PUMP .

Fig 12: High Pressure Fuel Pump & Roller Tappet
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the PCV (Positive crankcase ventilation) hose (A).

Fig 13: PCV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front engine hanger (A).

Fig 14: Front Engine Hanger
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cylinder head cover (A).

Fig 15: Cylinder Head Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.

Fig 16: Drive Belt, Tensioner & Belt Routing
Courtesy of KIA MOTORS AMERICA, INC.
Remove the A/C compressor lower bolts (A).

Fig 17: A/C Compressor Lower Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the A/C compressor bracket (A).

Fig 18: A/C Compressor Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Drain the engine oil.
Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and oil pan. Cut off applied sealer and remove the lower oil pan.

Fig 19: Removing Lower Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It is result in damage of the SST.
- Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
Set the jack to the edge of ladder frame.
NOTE: Put the wooden block between ladder frame and jack.

CAUTION: Be careful not to damage the balance shaft & oil pump module.
Disconnect the ground line (A), and then remove the engine mounting support bracket (B).

Fig 20: Ground Line & Engine Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).

Fig 21: Idler, Water Pump, Crankshaft & Drive Belt Tensioner Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left-handed screw.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3K000) to hold the ring gear after removing the starter.
  
  Fig 22: Holding Ring Gear
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
  
  Fig 23: Dust Cover & Transaxle Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
  
  Fig 24: Holder, Nuts, Ring Gear & Links
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 25: Tightening Bolts & Nuts Of Holder & Links
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the drive belt tensioner (A).

Fig 26: Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine support bracket (A).

Fig 27: Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block.

Fig 28: Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
Make sure that the key (A) of crankshaft is aligned with the mating surface of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 29: Identifying Key Of Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.
Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin (A) into the hole on the ratchet to hold the compressed piston. Remove the timing chain tensioner (B).

Fig 30: Identifying Stopper Pin & Timing Chain Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain tensioner arm (A).

Fig 31: Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain (A).

Fig 32: Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain guide (A).

Fig 33: Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).

Fig 34: Timing Chain Oil Jet & Crankshaft Chain Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the balance shaft chain. Refer to BALANCE SHAFT & OIL PUMP .