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Repair Procedures: Disassembly

WARNING: This page is about a different variant/trim than selected.
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) before removing it.
  • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Information 

  1. Remove the engine and transaxle assembly from the vehicle.

    (Refer to REMOVAL )

  2. Remove the transaxle assembly from the engine assembly.
  3. Remove the drive plate or flywheel.
    • Automatic Transaxle

      (Refer to Cylinder Block Assembly - "DRIVE PLATE ")

    • Manual Transaxle

      (Refer to Cylinder Block Assembly - "FLYWHEEL ")

  4. Remove the rear oil seal.

    (Refer to Cylinder Block Assembly - "REAR OIL SEAL ")

  5. Install the engine assembly to engine stand for disassembly.
  6. Remove the intake manifold.

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

  7. Remove the exhaust manifold.

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

  8. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  9. Remove the cylinder head assembly.

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

  10. Remove the oil filter.

    (Refer REPLACEMENT )

  11. Remove the oil pan and the oil screen.

    (Refer to Lubrication System - "OIL PAN ")

  12. Remove the ladder frame (A).
    Fig 1: Locating Ladder Frame
    G12226805Courtesy of KIA MOTORS AMERICA, INC.
  13. Check the connecting rod side clearance.
  14. Check the connecting rod bearing cap oil clearance.
  15. Remove the piston and connecting rod assembly.
    1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
    2. Remove the connecting rod bearing caps (A).
      Fig 2: Locating Connecting Rod Bearing Caps
      G12226806Courtesy of KIA MOTORS AMERICA, INC.

      Information 

      Mark the connecting rod and bearing caps to be able to reassemble in the original position and direction.

    3. Push the piston and connecting rod assembly with upper bearing through the top of the cylinder block.

      Information 

      • Keep the connecting rod and caps with the bearings assembled together.
      • Arrange the piston and connecting rod assemblies in the correct order.
      • Mark the piston and connecting rod assembly to be able to reassemble in the original position.
  16. 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.

  17. Disassemble the piston rings.
    1. Using a piston ring expender, remove the two compression rings.
    2. Remove the two side rails and coil spring.

    Information 

    Arrange the piston rings in the correct order.

  18. Disassemble the connecting rod from the piston.

    Using a hydraulic press, remove the piston pin from piston.

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