Repair Procedures: Removal

WARNING: This page is about a different car, the 2021 Kia Soul. However, it is still accessible from the selected car via links, so may be relevant.

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.

Remove the engine cover.
(Refer to Engine and Transmission Assembly - "ENGINE COVER ")
Disconnect the battery negative terminal.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Remove the engine room under cover.
(Refer to Engine and Transmission Assembly - "ENGINE ROOM UNDER COVER ")
Drain the coolant.
(Refer to Cooling System - "COOLANT ")
Remove the intercooler inlet hose & pipe (A).
Tightening torque

Hose clamp bolt:

4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft, 43.4 - 60.8 lb.in)

(If equipped with a cap, tighten it until the cap is removed.)

Pipe mounting Bolt:

18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

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Disconnect the RCV solenoid valve connector (A) and booster pressure sensor (BPS) connector (B).

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Disconnect the intercooler outlet hose (A).
Tightening torque:

4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft, 43.4 - 60.8 Ib.in)

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Disconnect the radiator upper hose (A).

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Disconnect the radiator lower hose (A).

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Disconnect the brake booster vacuum hose (A).

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Remove the intake & exhaust CVVT oil control valve.
(Refer to Engine Control/Fuel System - "CVVT OIL CONTROL VALVE (OCV) ")
Remove the vacuum pipe assembly (A).

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Remove the intake manifold.
(Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")
Remove the exhaust manifold module.
(Refer to Intake and Exhaust System - "REMOVAL AND INSTALLATION ")
Remove the delivery pipe assembly.
(Refer to Engine Control/Fuel System - "DELIVERY PIPE ")
Disconnect the bypass hose, and then remove the water temperature control assembly.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Remove the water pipe.
(Refer to Cooling System - "WATER TEMPERATURE CONTROL ASSEMBLY ")
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")
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)

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Remove the timing chain cover.
(Refer to Timing System - "TIMING CHAIN COVER ")
Remove the timing chain.
(Refer to Timing System - "TIMING CHAIN ")

Remove the intake CVVT assembly (A) & exhaust CVVT assembly (B).

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NOTE: When removing the CVVT assembly bolt, fix the camshaft (A) using a wrench.

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Remove the camshaft bearing caps (A) in the order of image below.

Fig 1: Camshaft Bearing Caps Removal Sequence
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Remove the intake & exhaust camshaft (A).

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Remove the rear hanger (A).

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Remove the cylinder head cover heat protector (A).

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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 2: 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).
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