Kia Optima Hybrid: Cooling System / Radiator Repair procedures

Inspection
Radiator Cap Testing
1.
Remove the radiator cap, wet its seal with engine coolant, and then install it on a pressure tester.

2.
Apply a pressure of 93.16 ~ 122.58kPa (0.95 ~ 1.25kgf/cm?, 13.51 ~ 17.78psi).
3.
Check for a drop in pressure.
4.
If the pressure drops, replace the cap.
Radiator Leakage Test
1.
Wait until engine is cool, then carefully remove the radiator cap and fill the radiator with engine coolant, then install it on the pressure tester (A).

2.
Apply a pressure tester to the radiator and apply a pressure of 93.16 ~ 122.58kPa (0.95 ~ 1.25kgf/cm?, 13.51 ~ 17.78psi).
3.
Inspect for engine coolant leaks and a drop in pressure.
4.
Remove the tester and reinstall the radiator cap.
   
Check for engine oil in the coolant and/or coolant in the engine oil.
Removal and Installation
1.
Disconnect the battery negative terminals. (Refer to Engine and transaxle assembly in this group)
2.
Remove the air cleaner assembly. (Refer to Engine and transaxle assembly in this group)
3.
Disconnect the fan motor connector (A).
4.
Remove the radiator upper hose clip (B).

5.
Remove the EWP(Electric water pump) inlet pipe mounting bolts (A).

6.
Remove the cooling fan assembly (A).

Tightening torque :
4.9 ~ 7.8 N.m (0.5 ~ 0.8 kgf.m, 3.6 ~ 5.8 lb-ft)

7.
Remove the under cover. (Refer to Engine and transaxle assembly in this group)
8.
Loosen the drain plug (A), and drain the engine coolant. Remove the radiator cap to help drain the coolant faster.

9.
Disconnect the over flow hose (A) from the radiator.

10.
Disconnect the radiator upper hose (A) and lower hose (B).

11.
Remove the radiator mounting brackets (A).

Tightening torque:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

12.
Drain the inverter coolant and then disconnect the inverter radiator hoses. (Refer to HT group - "Coolant")
13.
Separate the condenser from the radiator and then remove the radiator assembly (A).

14.
Disassemble the inverter radiator (A) from the radiator assembly (B). (Refer to HT group - "Radiator")

15.
Installation is the reverse order of removal.
16.
Fill the radiator with coolant and check for leaks.
   
Bleed air from the hybrid motor cooling system prior to the engine 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 engine. Check the coolant level and add coolant if needed. This will allow trapped air to be removed from the cooling system.
Put the radiator cap on tightly, then run engine again and check for leaks.
Radiator Components and Components Location

Components 1. Cooling fan assembly2. Radiator assembly3. Mounting insulator4. Radiator mounting bracket5. Radiator upper hose6. Radiator lower hose7. Reservoir tank8. Over flow hose ...

Water pump Components and Components Location

Components 1. Water pump pulley2. Dust cover3. Water pump sub assembly (Water pump housing)4. Water pump housing gasket5. Water pump cover6. Water pump gasket7. Water inlet pipe gasket (O-ring)8. Water ...

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