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 automatic transaxle. (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. (Refer to " Disassembly  ") 
17. Remove the crankshaft. (Refer to " Disassembly  ") 
18. Remove the water jacket insert. (Refer to " Removal and Installation  ") 
19. Remove the knock sensor. (Refer to " Removal  ") 
20. Remove the crankshaft position sensor (CKPS). (Refer to " Removal  ") 
21. Remove the piston cooling oil jet (A).

    Courtesy of KIA MOTORS AMERICA, INC.