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Home >> Kia >> 2017 >> Optima Plug-In Hybrid EX >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Engine And Transaxle Assembly (R & I) (PHEV) >> Engine And Transaxle Assembly >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING:
  • Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
  • Be sure to shut off the high voltage circuit according to the "High Voltage shutoff Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries.
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
  • 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.

Information 

Mark all wiring and hoses to avoid misconnection.

  1. Shut off the high voltage circuit.

    (Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT OFF PROCEDURE ")

  2. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  3. Remove the air cleaner assembly.

    (Refer to Intake And Exhaust System - "AIR CLEANER ")

  4. Remove the engine room under cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  5. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  6. Drain the inverter coolant.

    (Refer to Hybrid Motor System - "COOLANT ")

  7. Disconnect the radiator upper hose (A).
    G12352944Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the radiator lower hose (A).
    G12352945Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the hybrid power control unit (HPCU) and tray.

    (Refer to Hybrid Control System - "HYBRID POWER CONTROL UNIT (HPCU) ")

  10. Disconnect the fuse box main wiring connector (A).
    G12352946Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the Engine Control Module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  12. Remove the engine wiring.
    1. Disconnect the ground cable (A).
    2. Remove the main wiring protector (B).
    G12352947Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the electric oil pump (EOP) connector (A) and clutch pressure sensor (CPS) connector (B).
    G12352948Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect the electric oil pump (EOP) unit high voltage connector (A).
    G12352949Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the electric water pump (EWP) water pipe (A) from the intake manifold.

    Tightening Torque: 

    8.8 - 10.9 N.m (0.9 - 1.1 kgf.m, 6.5 - 8.0 lb.ft)

    G12352950Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the hybrid starter generator (HSG) water hose (A).
    G12352951Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the fuel hose (A) and purge control solenoid valve (PCSV) hose (B).
    G12352952Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the front oxygen sensor connector (A), rear oxygen sensor connector (B) and exhaust camshaft position sensor connector (C).
    G12352953Courtesy of KIA MOTORS AMERICA, INC.
  19. Disconnect the ignition coil connector (A) and intake camshaft position sensor connector (B).
    G12352954Courtesy of KIA MOTORS AMERICA, INC.
  20. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

    (Refer to Heating, Ventilation Air conditioning - "COMPRESSOR ")

  21. Remove the transaxle wire harness connectors and control cable from the transaxle.

    (Refer to Automatic Transaxle System - "AUTOMATIC TRANSAXLE ")

  22. Disconnect the heater hose (A).
    G12352955Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the front muffler.

    (Refer to Intake and Exhaust System - "MUFFLER ")

  24. Remove the roll rod bracket (A).

    Tightening Torque 

    Bolts (B): 107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb.ft)

    Bolts (C): 49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb.ft)

    G12352956Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use new bolt (B).
  25. Remove the roll rod mounting support bracket (A).

    Tightening Torque: 

    49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb.ft)

    G12352957Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the sub frame. (Refer to Suspension system - "SUB FRAME ")
  27. Support the engine and transaxle assembly on a lift table.
  28. Disconnect the ground cable (A) and then remove the engine mounting support bracket (B).

    Tightening Torque 

    Ground cable: 10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 8.0 - 10.1 lb.ft)

    Support bracket: 88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb.ft)

    G12352958Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use new nuts.
  29. Disconnect the transaxle ground cable (A).
    G12352959Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the transaxle mounting side panel packing (A).
    G12352960Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the transaxle mounting bolts (A).

    Tightening Torque: 

    107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb.ft)

    G12352961Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use a new bolts.
  32. Remove the engine and transaxle assembly by lifting vehicle.
G12352962Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
  • Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
  • When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
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