Kia Optima Hybrid: Front Suspension System / Front Cross Member Repair procedures

Replacement
1.
Remove the front wheel & tire.

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

   
Be careful not to damage to the hub bolts when removing the front wheel & tire.
2.
Loosen the bolt (A) and then disconnect the universal joint assembly from the pinion of the steering gear box.

Tightening torque:
29.4 ~ 34.3N.m(3.0 ~ 3.5kgf.m, 21.7 ~ 25.7lb-ft)

   
Lock the steering wheel in the straight ahead position to prevent the damage of the clock spring inner cable when you handle the steering wheel.
3.
Remove the split pin and castle nut and then disconnect the tie-rod end (A) from the front knuckle.

Tightening torque:
34.3 ~ 44.1N.m(3.5 ~ 4.5kgf.m, 25.7 ~ 32.5lb-ft)

4.
Loosen the bolt & nut and then remove the lower arm (A).

Tightening torque:
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

5.
Remove the front lower arm from the front knuckle using the SST (0K545-A9100).
(1)
After removing bolts from the front knuckle, install and tighten the sub body bolt (A) .

(2)
Input the sub body (A) between the front knuckle and the sub body bolt.
(3)
Tighten bolt (B) of the sub body bolt to broaden the gap of the front knuckle.

(4)
Install the safe wire (A).

   
Install a safe wire on the front strut to prevent dropping the SST and hurting technicians.
(5)
Install the main body, between the front strut and the lower arm.

(6)
To avoid the main body coming off, install a fixing clamp (A) beside the main body.

(7)
After installing a fixing clamp, rotate the handle (B) clock wise till the clamp is fixed on a lower arm.

(8)
Tighten a main body bolt (A) of the slowly and remove the lower arm from the front knuckle.

6.
Disconnect the stabilizer link (B) with the front strut assembly (A) after loosening the nut.

Tightening torque:
98.1 ~ 117.7N.m(10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

7.
Remove the undercover (A).

8.
Loosen the bolt (A) & nut (B) and then remove the roll rod stopper (A).

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

9.
Disconnect the muffler rubber hanger (A).

10.
Loosen the bolts & nuts and then remove the sub frame (A).

Tightening torque
Sub frame mounting bolts & nuts:
156.9 ~ 176.5N.m (16.0 ~ 18.0kgf.m, 115.7 ~ 130.2lb-ft)
Sub frame stay bolts & nuts:
44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

11.
Remove the front lower arm.
(Refer to Front lower arm)
12.
Remove the front stabilizer.
(Refer to Front stabilizer)
13.
Remove the steering gearbox.
(Refer to ST group - "Steering Gearbox")
14.
Installation is the reverse of removal.
Front Stabilizer Bar Repair procedures

Replacement 1. Remove the front wheel & tire. Tightening torque: 88.3 ~ 107.9N.m(9.0 ~ 11.0kgf.m, 65.1~79.6lb-ft)     Be careful not to damage to the hub bolts when removing the front wheel ...

Rear Suspension System

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Other information:

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Heated Oxygen Sensor (HO2S) Repair procedures


Inspection 1. Turn the ignition switch OFF. 2. Disconnect the HO2S connector. 3. Measure resistance between the HO2S terminals 4 and 5 [B1/S1]. Measure resistance between the HO2S terminals 3 and 4 [B1/S2]. 4. Check that the resistance is within the specification. HO2S [Bank 1/Sensor 1] (Linear type) ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Brake Line Repair procedures


Removal 1. Disconnect the brake fiuid level switch connector, and remove the reservoir cap. 2. Remove the brake fluid from the master cylinder reservior with a syringe.     Do not spill brake fluid on the vehicle, it may damage the paint; if brake fluid does contact the paint, wash it off immediately ...

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