Repair Procedures: Removal

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

Engine removal is not required for this procedure.

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 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

Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.
1. Remove the engine cover.
  (Refer to Engine and Transmission Assembly - "ENGINE COVER ")
2. Disconnect the battery negative terminal.
3. Remove the air duct and air cleaner assembly.
  (Refer to Intake and Exhaust System - "AIR CLEANER ")
4. Remove the engine room under cover.
  (Refer to Engine and Transmission Assembly - "ENGINE ROOM UNDER COVER ")
5. Drain the coolant.
  (Refer to Cooling System - "COOLANT ")
6. Remove the intercooler inlet hoses & pipe (A).
  Tightening torque
  
  Bolt:
  
  19.6 - 26.4 N.m (2.0 - 2.7 kgf.m, 14.4 - 19.5 lb.ft)
  
  Clamp:
  
  4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)
  
  Fig 1: Locating Intercooler Inlet Hoses And Pipe
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the RCV solenoid valve hose (A), radiator upper hose (B) and intercooler outlet hose (C).
  Tightening torque:
  
  4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)
  
  Fig 2: Locating RCV Solenoid Valve Hose, Radiator Upper Hose And Intercooler Outlet Hose
  Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the radiator lower hose (A).
  
  Fig 3: Locating Radiator Lower Hose
  Courtesy of KIA MOTORS AMERICA, INC.
9. Disconnect the brake booster vacuum hose (A).
  
  Fig 4: Locating Brake Booster Vacuum Hose
  Courtesy of KIA MOTORS AMERICA, INC.
10. Disconnect the heater hoses (A).
  
  Fig 5: Locating Heater Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
11. Remove the intake & exhaust CVVT oil control valve.
  (Refer to Engine Control/Fuel System - "CVVT OIL CONTROL VALVE (OCV) ")
12. Remove the vacuum pipe assembly (A).
  
  Fig 6: Locating Vacuum Pipe Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
13. Remove the intake manifold.
  (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
14. Remove the exhaust manifold module.
  (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")
15. Remove the delivery pipe assembly.
  (Refer to Engine Control/Fuel System - "DELIVERY PIPE ")
16. Disconnect the bypass hose, and then remove the water temperature control assembly.
  (Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
17. Remove the water pipe.
  (Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
18. Remove the cylinder head cover.
  (Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")
19. Remove the exhaust oil control valve (OCV) adapter (A).
  Tightening torque:
  
  9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)
  
  Fig 7: Removing Exhaust Oil Control Valve Adapter
  Courtesy of KIA MOTORS AMERICA, INC.
20. Remove the timing chain cover.
  (Refer to Timing System - "TIMING CHAIN COVER ")
21. Remove the timing chain.
  (Refer to Timing System - "TIMING CHAIN ")
22. Remove the intake CVVT assembly (A) & exhaust CVVT assembly (B).
  
  Fig 8: Removing Intake CVVT Assembly And Exhaust CVVT Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: When removing the CVVT assembly bolt, fix the camshaft (A) using a wrench.
  
  Fig 9: Fixing Camshaft Using Wrench
  Courtesy of KIA MOTORS AMERICA, INC.
23. Remove the camshaft bearing caps (A) in the order of image below.
  
  Fig 10: Camshaft Bearing Caps Loosening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
24. Remove the intake & exhaust camshaft (A).
  
  Fig 11: Locating Intake And Exhaust Camshaft
  Courtesy of KIA MOTORS AMERICA, INC.
25. Remove the rear hanger (A).
  
  Fig 12: Locating Rear Hanger
  Courtesy of KIA MOTORS AMERICA, INC.
26. Remove the cylinder head cover heat protector (A).
  
  Fig 13: Locating Cylinder Head Cover Heat Protector
  Courtesy of KIA MOTORS AMERICA, INC.
27. Remove the cylinder head bolts, then remove the cylinder head.
  1. Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
    
    Fig 14: Cylinder Head Bolts Loosening Sequence
    Courtesy of KIA MOTORS AMERICA, INC.
    
    NOTE: Head warpage or cracking could result from removing bolts in an incorrect order.
  2. Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks.
    NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
  3. Remove the cylinder head gasket (B).
    
    Fig 15: Locating Cylinder Head And Cylinder Head Gasket
    Courtesy of KIA MOTORS AMERICA, INC.