Kia Optima Hybrid: Engine And Transaxle Assembly / Engine And Transaxle Assembly Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Engine Mechanical System / Engine And Transaxle Assembly / Engine And Transaxle Assembly Repair procedures

Removal

•	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.

•	Mark all wiring and hoses to avoid misconnection.

•	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 Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.

1.	Shut off the High Voltage circuit (Refer to “High Voltage Shutoff Procedure” in this group).

2.	Remove the engine cover (A).

Remove the air duct (A).

Tightening torque:

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Remove the air cleaner assembly.

(1)	Disconnect the breather hose (A).

(2)

Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).

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)

•	When installing the air intake hose, the plate of the hose clamp must be in line with the stopper of the hose.

•	When installing the air intake hose, the center of the mark of hose must be in line with the throttle body rib.

Remove the under covers (A, B).

Tightening torque:

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.

6.	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)

7.	Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to HT group - "Coolant")

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

9.	Remove the hybrid power control unit (HPCU). (Refer to HC group - "HPCU")

10.

Remove the inverter tray (A).

Tightening torque:

8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

11.	Recover the refrigerant and then remove the high pressure pipe (A) and low pressure pipe (B). (Refer to HA Group - "Electric A/C compressor")

12.	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).

13.	Disconnect the cooling hoses from hybrid starter generator (HSG) (A) and electric water pump (EWP) (B).

14.	Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to AT group).

15.	Disconnect the heater hoses (A).

16.	Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

17.	Remove the front muffler (A).

18.	Remove the steering u-joint mounting bolt (A). (Refer to ST group)

19.	Remove the front wheels. (Refer to SS group - "Wheel")

20.	Remove the lower arms (A). (Refer to SS group - "Front lower arm")

21.	Remove the stabilizer bar links (A). (Refer to SS group - "Front stabilizer bar")

22.	Remove the tie rod ends (A). (Refer to ST group - "Steering gear box")

23.	Disconnect the drive shafts (A) from the axle hubs. (Refer to DS group - "Front hub / knuckle")

24.

Remove the roll rod bracket (A).

Tightening torque:

Bolt (B) :

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

Bolt (C) :

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

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)

26.

Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. (Refer to SS group - "Front cross member")

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)

•	After removing the sub frame mounting bolts and nuts, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.

•	Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.

27.	Support the engine and transaxle assembly with a floor jack.

28.

Disconnect the engine ground cable (A).

Tightening torque :

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

29.

Remove the engine mounting support bracket (B).

Tightening torque:

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

30.	Disconnect the transaxle ground line (A)

31.

Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A)

Tightening torque :

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

32.

Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle.

When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation

Installation is in the reverse order of removal.

Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.

•	Adjust a shift cable.

•	Refill engine with engine oil.

•	Refill a transaxle with fluid.

•	Refill an engine radiator and a reservoir tank with coolant.

•	Refill an inverter radiator and a reservoir tank with coolant.

•	Clean battery posts and cable terminals and assemble.

•	Inspect for fuel leakage.

–	After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.

–	Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

•	Bleed air from the hybrid motor cooling system. (Refer to HT group - "Coolant")

•	Bleed air from the engine cooling system.

–	Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)

–	Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.

–	Put radiator cap on tightly, then run the engine again and check for leaks.

The HCU need to learn the mesh point for the engine clutch to reduce shock while engine power is connected to the transaxle. Perform the Clutch Pressure Sensor Calibration after installing the CPS, HCU, engine or hybrid drive motor (Refer to "Hybrid Control System" in HC group).

Engine Mounting Components and Components Location - Revised

Components 1. Engine mounting support bracket2. Engine mounting bracket3. Roll rod bracket4. Transaxle mounting bracket 5. Sub frame ...

Timing System

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