Repair Procedures: Removal

Engine removal is not required for this procedure.

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE: Mark all wiring and hoses to avoid misconnection.

WARNING: In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

Remove the engine cover.
Disconnect the battery negative terminal (A).

Fig 1: Locating Battery Negative Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Remove the air duct (A).
2. Disconnect the breather hose (B).
3. Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
Fig 2: Locating Intake Hose, Air Cleaner Assembly, Breather Hose And Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH front wheel.
Remove the under covers (A).

Fig 3: Removing Under Covers
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).

Fig 4: Locating A/C Compressor Switch Connector, Alternator Connector And Alternator B Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the intake OCV (Oil Control Valve) connector (A) and the exhaust OCV (Oil Control Valve) connector (B).

Fig 5: Locating Intake Oil Control Valve Connector And Exhaust Oil Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable Intake System) connector (C) and the PCSV (Purge Control Solenoid Valve) connector (D).

Fig 6: Locating Ignition Coil Connectors, Injector Extension Connector, VIS Connector And PCSV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the FPCV (Fuel Pressure Control Valve) connector (A), the intake CMPS (Camshaft Position Sensor) connector (B) and the exhaust CMPS (Camshaft Position Sensor) connector (C).

Fig 7: Locating FPCV Connector, Intake And Exhaust CMPS Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the oxygen sensor connectors (A) and the condenser connector (B).

Fig 8: Locating Oxygen Sensor Connectors And Condenser Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel hose (A) and the PCV (Positive Crankcase Ventilation) hose (B).

Fig 9: Locating Fuel Hose And PCV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the vacuum pipe assembly (A).

Fig 10: Removing Vacuum Pipe Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure pipe (A). (Refer to DELIVERY PIPE )

Fig 11: Locating High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to HIGH PRESSURE FUEL PUMP )

Fig 12: Removing High Pressure Fuel Pump And Roller Tappet
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ignition coils (A).

Fig 13: Removing Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust OCV (Oil Control Valve) (B).

Fig 14: Removing Exhaust Oil Control Valve
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cylinder head cover (A) with gaskets (B).

Fig 15: Locating Cylinder Head Cover And Gaskets
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust OCV (Oil control valve) adapter (A).

Fig 16: Removing Exhaust Oil Control Valve Adapter
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the water pump pulley bolt and the drive idler mounting bolt.
Loosen the alternator tension adjusting bolt (A) to loosen tension.

Fig 17: Loosening Alternator Tension Adjusting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the alternator drive belt (A).

Fig 18: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ALTERNATOR (A). (Refer to REMOVAL ).

Fig 19: Removing Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the ground line (A) and then remove the engine mounting support bracket (A).

Fig 20: Removing Engine Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Support the engine with a jack not to be tilted.
Remove the alternator bracket (B).
Remove the engine support bracket (A).

Fig 21: Locating Engine Support Bracket And Alternator Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the water pump pulley (A) and the drive belt idler (B).

Fig 22: Removing Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Remove the water pump (A).

Fig 23: Locating Water Pump
Courtesy of KIA MOTORS AMERICA, INC.
Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.

Fig 24: Aligning Crankshaft Pulley Groove With Timing Mark Of Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the crankshaft bolt (B) and crankshaft pulley (A).

Fig 25: Locating Crankshaft Bolt And Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 26: Holding Ring Gear With SST (09231-2B100)
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the bracket (A).
  
  Fig 27: Removing Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
  
  Fig 28: Locating Dust Cover And Transaxle Mounting Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4. Adjust the angle of the links (D), and fasten the bolt 70 mm (2.7559 in) in the original mounted hole.
  
  Fig 29: Adjusting Length Of Holder Nuts
  Courtesy of KIA MOTORS AMERICA, INC.
5. Tighten the bolts and nuts of the holder and links securely.
Fig 30: Tightening Bolts And Nuts Of Holder And Links
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain cover (A).

Fig 31: Locating Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not disassemble the oil pump (A) from timing chain cover because it is supplied as timing chain cover & oil pump assembly.
Align the timing marks of the Continuous variable valve timing (CVVT) sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at top dead Center (TDC).
1. Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
  CAUTION: Put paint marks on the timing chain links (3 places) that meet with the timing marks of the CVVT sprockets (In, Ex: 2) and the CVVT sprocket.
  
  Fig 32: Locating Timing Marks Of Continuous Variable Valve Timing Sprockets
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 33: Locating Timing Chain Links With Paint Marks
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the hydraulic tensioner (A).

Fig 34: Locating Hydraulic Tensioner
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Before removing the tensioner, fix the piston of the tensioner with a pin through the hole (B) at compressed position.
Remove the timing chain tensioner arm (A) and guide (B).

Fig 35: Locating Timing Chain Tensioner Arm And Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain (A).

Fig 36: Locating Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.