Repair Procedures: Disassembly

Information 

• Mark all wiring and hoses to avoid misconnection.
• After starting the engine to release the pressure inside the fuel line, remove the fuel pump relay. Turn off the ignition after the engine stops because the fuel line is exhausted.
• Rotate the crankshaft and position the piston of cylinder 1 at the compression upper dead point.

1. Remove the engine and transaxle assembly.

   (Refer to " Removal  ") 

2. Disconnect the wiring connectors and harness clamps and remove the connector brackets around the engine and transaxle assembly.

   Courtesy of KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

3. Remove the transaxle assembly from the engine assembly. (Refer to " Removal  ") 
4. Remove the drive plate. (Refer to " Removal and Installation  ") 
5. Remove the rear oil seal. (Refer to " Replacement  ") 
6. Install the engine to engine stand for disassembly.
7. Remove the oil pan. (Refer to " Removal  ") 
8. Remove the timing chain. (Refer to " Removal  ") 
9. Remove the intake manifold. (Refer to " Removal And Installation  ") 
10. Remove the turbocharger and exhaust manifold. (Refer to " Removal And Installation  ") 
11. Remove the electronic EGR control valve. (Refer to " Removal  ") 
12. Remove the EGR cooler. (Refer to " Removal And Installation  ") 
13. Remove the oil filter and oil cooler. (Refer to " Removal And Installation  ") 
14. Remove the oil pump. (Refer to " Removal And Installation  ") 
15. Remove the cylinder head. (Refer to " Removal  ") 
16. Remove the piston and connecting rod assembly.
    1. Remove the carbon deposits on the top of cylinder.
    2. Remove the connecting rod bearing caps (A).

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       Information 

       Mark the cylinder number on the connecting rod and cap so that it can be fitted in the correct position when reassembling.

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

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    NOTE:

    • Keep the connecting rod and cap with the bearing assembled.
    • Arrange the piston and connecting rod assemblies in the correct order.
17. Measure the clearance between the 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 piston pin as a set.

18. Remove piston rings.
    1. Remove the 2 piston rings (A) using a piston ring expander.
    2. Remove the oil ring (B) with hand.
19. Remove the piston and connecting rod.
    1. Remove the snap ring (C).
    2. Remove the piston pin (D) from the piston.
    3. Separate the piston (E) and connecting rod (F).

Courtesy of KIA MOTORS AMERICA, INC.