Kia Optima: Removal
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Use fender covers to
avoid damaging painted surfaces. |
| • |
To avoid damage, unplug
the wiring connectors carefully while holding the connector portion. |
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| • |
Mark all wiring and hoses
to avoid misconnection. |
| • |
To release the fuel system
pressure before removing the engine assembly, start the engine with
the fuel pump relay removed. And then turn off the ignition switch
after engine stops. |
|
| 1. |
Remove the engine cover. |
| 2. |
Disconnect the battery terminals
(A).
Tightening torque :(+)
terminal : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
(-) terminal : 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
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| 3. |
Remove the air duct (B).
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| 4. |
Remove the battery (A) after
removing the mounting bracket (B).
Tightening torque:9.8 ~
11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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| 5. |
Remove the air cleaner assembly.
| (1) |
Disconnect the breather
hose (A), the recirculation hose (B) and the brake booster vacuum
hose (C). |
| (2) |
Disconnect the air intake
hose (D) and then remove the air cleaner assembly (E).
Tightening torque
Hose clamp bolt:
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner assembly bolts:
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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| 6. |
Remove the battery tray (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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| 7. |
Remove the intercooler inlet
hose (A).
Tightening torque:4.9 ~
6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
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| 8. |
Disconnect the recirculation
valve connector (A) and the vacuum hose (B), and then remove the intercooner
inlet pipe & hose assembly (C)
Tightening torquePipe mounting
bolt:
14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)
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| 9. |
Disconnect the boost pressure
sensor connector (A) and then remove the intercooner outlet pipe & hose
assembly (B).
Tightening torque4.9 ~
6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
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| 10. |
Remove the under covers (A,B).
Tightening torque:9.8 ~
11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
|
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When removing the under cover (B), unfasten the mounting bracket
bolts and then remove the under cover and mounting bracket assembly. |
|
| 11. |
Loosen the drain plug, and drain
the engine coolant. Remove the radiator cap to drain with speed. (Refer
to Cooling system in this group) |
| 12. |
Disconnect the radiator upper
hose (A) and lower hose (B).
|
| 13. |
Recover the refrigerant and then
remove the high pressure pipe and low pressure pipe (A). (Refer to Air conditioning
system in HA Group.)
|
| 14. |
Disconnect the (+) cable (A)
from the fuse/relay box and the front connector (B). Then remove the wiring
protector (C).
|
| 15. |
Disconnect the ECM connectors
(A) from the ECM, the fuse box connector (B) from the fuse/relay box and
the engine ground line (C). Then remove the wiring protector (D)..
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| 16. |
Remove the transaxle wire harness
connectors (A) and control cable (B) from the transaxle. (Refer to AT or
MT group).
|
| 17. |
Disconnect the ATF cooler hoses
(A).
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| 18. |
Disconnect the intensifier hose
(A) and the vacuum hose (B).
|
| 19. |
Disconnect the fuel hose (A)
and PCSV (Purge control solenoid valve) hose (B).
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| 20. |
Disconnect the heater hoses (A).
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| 21. |
Remove the front muffler (B)
after disconnecting the front oxygen sensor connector (A).
Tightening torque:39.2
~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
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| 22. |
Remove the steering u-joint mounting
bolt (A). (Refer to ST group)
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| 23. |
Remove the front wheels. |
| 24. |
Remove the lower arms (A). (Refer
to SS group)
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| 25. |
Remove the stabilizer bar links
(A). (Refer to SS group)
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| 26. |
Remove the tie rod ends (A).
(Refer to ST group)
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| 27. |
Disconnect the drive shafts from
the axle hubs. (Refer to DS group) |
| 28. |
Remove the roll rod bracket (A).
Tightening torque:Nut (B)
: 88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Bolt (C) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
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| 29. |
Support the sub frame (A) with
a floor jack, and then remove the sub frame mounting bolts and nuts.
Tightening torque:Sub frame
mounting bolts & nuts :
156.9 ~ 176.5 N.m (16.0 ~ 18.0 kgf.m, 115.7 ~ 130.2 lb-ft)Stay
mounting bolts :
44.1 ~ 58.8 N.m (4.5 ~ 6.0 kgf.m, 32.5 ~ 43.4 lb-ft)
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| •
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After removing
the sub frame mounting bolt, the engine and transaxle assembly
may fall downward, and so support them securely with floor
jack. |
| •
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Verify that the
hoses and connectors are disconnected before removing the
engine and transaxle assembly. |
|
|
| 30. |
Disconnect the ground line (A),
and then remove the engine mounting support bracket (B).
Tightening torque:78.5
~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)
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| 31. |
Disconnect the ground line (A),
and then remove the transaxle mounting support bracket (B).
Tightening torque:88.3
~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
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| 32. |
Remove the engine and transaxle
assembly by lifting vehicle.
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When remove the engine and transaxle assembly, be careful not to
damage any surrounding parts or body components. |
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Installation is in the reverse order of removal.
Perform the following :
•
Adjust a shift cable.
•
Refill engine with engine oil.
•
Refill a transaxle with ...
Installation