Kia Rio: Removal

Engine removal is not required for this procedure.

•	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.

Mark all wiring and hoses to avoid misconnection.

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.

1.	Remove the engine cover.

2.	Disconnect the battery terminals (A).

Remove the air cleaner assembly.

(1)	Remove the air duct (A)

(2)	Disconnect the breather hose (B) and the air intake hose (C)

(3)	Remove the air cleaner assembly (D)

4.	Remove the battery (A) after removing the mounting bracket.

5.	Disconnect the ECM connectors (A) and then remove the ECM (B) and battery tray (C).

6.	Remove the RH front wheel.

7.	Remove the under covers (A).

8.	Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to Cooling system in this group)

9.	Disconnect the radiator upper hose (A) and lower hose (B).

10.

Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.

(1)	The A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator “B” terminal (C)

(2)	The intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B)

(3)	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)

(4)	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)

(5)	Disconnect the oxygen sensor connectors (A) and the condenser connector (B)

(6)	The ECTS (Engine coolant temperature sensor) connector (A) and the ground line (B)

(7)	The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B)

11.	Disconnect the brake booster vacuum hose (A) and heater hose (B).

12.	Disconnect the fuel hose (A), the PCV (Positive crankcase ventilation) hose (B) and the PCSV (Purge control solenoid valve) hose (C).

13.	Remove the vacuum pipe assembly (A).

14.	Remove the high pressure pipe (A). (Refer to FL group)

15.	Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to FL group)

16.	Remove the ignition coils (A).

17.	Remove the exhaust OCV (Oil control valve) (B).

18.	Remove the cylinder head cover (A) with gaskets (B).

19.	Remove the exhaust OCV (Oil control valve) adapter (A).

20.	Remove the timing chain. (Refer to Timing system in this group)

21.	Remove the exhaust manifold assembly. (Refer to Intake and exhaust system in this group)

22.	Remove the intake manifold module assembly. (Refer to Intake and exhaust system in this group)

23.

Remove the intake continous variable vavle timing (CVVT) assembly (A) and exhaust continous variable vavle timing (CVVT) assembly (B).

When removing the continous variable vavle timing (CVVT) assembly bolt, prevent the camshaft from rotating by using a wrench at position (A).

24.	Remove the camshaft bearing caps (A) with the order below.

25.	Remove the camshafts (A).

26.	Remove the injector & rail assembly (A). (Refer to FL group)

27.	Remove the water temperature control assembly (B) after disconnecting the throttle body cooling hose (A).

28.	Remove the heater pipe (A).

29.	Remove the intake OCV (Oil Control Valve) (A).

30.

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.

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.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Components

1. Cylinder head cover 2. Cylinder head cover gasket 3. Cylinder head assembly 4. Cylinder head gasket 5. Camshaft position sensor 6. Camshaft bearing cap 7. Camshaft ...

Disassembly

Identify MLA(Mechanical lash adjuster), valves, valve springs as they are removed so that each item can be reinstalled i ...

Kia Rio: Removal

Components

Disassembly

See also:

Categories