Removal & Installation - A/t: Other Kia Optima I

SEPHIA

Note. Anytime battery cables are disconnected from battery and then reconnected, theft deterrent system will be activated (horn will sound and emergency lights will flash about 3 minutes). To disarm theft deterrent system, insert ignition key and turn key to ACC position.

1. Disconnect negative battery cable. Raise and support vehicle. Drain transaxle. Remove No. 4 engine mount bolts (top of transmission). Remove wheels and splash shields. Disconnect air hose, and remove air cleaner and resonance chamber. Remove battery and battery tray. Disconnect input/turbine speed sensor and Vehicle Speed Sensor (VSS) electrical connectors from transaxle.
2. Remove ground strap from top bellhousing bolt. Disconnect Transmission Range (TR) switch and solenoid valve electrical connectors. Disconnect shift cable from transaxle. Disconnect oxygen sensor and crankshaft position sensor electrical connectors. Disconnect ATF cooler lines. Remove 2 upper bell housing bolts. Support engine from above using Engine Support Assembly (0K201-170-AA0) or equivalent.
3. Remove "U" bolts retaining catalytic converter, nuts from exhaust flanges and remove catalytic converter. Remove front torque converter housing access plates and cover. Mark converter and drive plate for reassembly reference, and remove torque converter bolts. Remove bolts retaining starter assembly, and set starter aside. Remove engine oil pan-to-transaxle bolts.
4. Disconnect both left and right side tie rod ends from knuckles. Remove stabilizer bar. Remove lower ball joint-to-steering knuckle pinch bolts. Separate lower control arm from steering knuckle. Remove nuts retaining No. 2 engine mount to crossmember. Remove bolts (front) and nuts (rear) retaining crossmember to chassis, and remove crossmember.
5. Remove bolts retaining joint shaft support bracket to engine block. Separate left axle shaft from transaxle using pry bar inserted between axle shaft and case. DO NOT damage oil seal. Install Differential Side Gear Holder (K94A-4208-AT) into differential side gear opening (to prevent side gears from becoming misaligned). Separate right axle shaft from transaxle.
6. Remove No. 1 engine mount bolts (right side of transmission). Remove No. 2 engine mount bolts (left side of transmission) and remove No. 2 engine mount. Support transaxle from below using transmission jack. Slightly lower engine using engine support from above. Remove 2 remaining transaxle-to-engine bolts. Slowly lower transaxle assembly while separating transaxle from engine assembly.

1. To install transaxle, reverse removal procedure. Torque converter is seated properly when distance between engine mating service of converter housing and face of converter is.54" (14 mm).
2. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-123311-S39201864202001091900000) . Install NEW clips onto axle shaft ends before installing axle shafts. For more information on axle shafts. See appropriate FWD AXLE SHAFTS article in DRIVE AXLES. Fill transaxle with required amount of fluid, and check for external leaks.

1. Disconnect negative battery cable. Disconnect throttle cable from throttle body. Slide front seats forward, and remove rear console mounting screws. Set parking brake. Remove rear console by sliding up and over parking brake lever. Slide front seats rearward. Remove screws from front console. Untie transfer case shift lever boot, and enlarge opening enough for lever to pass through.
2. Remove transfer case shift lever knob. Pull rear of front console slightly up and rearward until power/economy switch connector is exposed. Disconnect connector, and remove console. Move transfer case shift lever to 4L position. Remove transfer case shift lever cover plate and boot. Remove shift lever assembly bolts and remove shift lever by pulling straight up. Cover opening with tape or cardboard to prevent entry of foreign material.
3. Place gearshift selector in "P" position and remove selector lever assembly nuts. Raise and support vehicle. Remove selector rod from transmission gear selector lever. Drain transmission fluid into suitable container. Lower vehicle. Disconnect electrical connectors from underneath selector assembly. Carefully tilt and rotate selector assembly and remove assembly.
4. From engine compartment, ensure transmission cable is disconnected from throttle body and all brackets. Pull upper dipstick tube free of lower dipstick tube. Raise and support vehicle. Disconnect input/turbine speed sensor located on top rear driver's side of transmission. Disconnect shift solenoid valves located on lower rear driver's side of transmission. Disconnect Vehicle Speed Sensor (VSS) electrical connector located on center driver's side of transfer case. Disconnect input speed sensor electrical connector located on top front driver's side of transmission.
5. Place alignment marks on front and rear drive shaft flanges and remove drive shafts. Disconnect transmission oil cooler lines from radiator and transmission and remove oil cooler lines from vehicle. Remove intake manifold bracket (if equipped), then remove starter. Remove transfer case mount bolts, located on passenger's side, center of transfer case. Remove transfer case nuts from crossmember.
6. Place transmission jack under transmission, and position as close to crossmember as possible. Secure transmission to jack. Remove crossmember bolts (4 on each side) and remove crossmember. Remove transmission-to-engine bolts. Raise transmission slightly. Remove front lower splash guard. Remove driver-side lower gusset and torque converter inspection cover. Remove torque converter bolts. Slide transmission rearward and lower slightly.
7. Remove crankshaft position sensor bolt and sensor. Lower transmission slightly guiding throttle cable out of engine compartment. Disconnect 4WD indicator switch and 4WD low switch connectors. Continue to lower transmission while checking above and around transmission. Disconnect or set aside items that get caught on transmission when lowering transmission.

1. Raise transmission enough to connect upper electrical connectors. Continue raising transmission while guiding throttle cable into engine compartment and into position. Continuously check above and around transmission, ensuring all connectors are connected and transmission does not get caught on wiring harnesses.
2. To complete installation, reverse removal procedure. Tighten fasteners to specifications. See «TORQUE SPECIFICATIONS»(ref-123311-S39201864202001091900000) . Fill transmission with required amount of fluid, and check for leaks.

OPTIMA & MAGENTIS (CANADIAN)

TORQUE SPECIFICATIONS (OPTIMA & MAGENTIS (CANADIAN))

RIO

TORQUE SPECIFICATIONS (RIO)

TORQUE SPECIFICATIONS (SEPHIA)

SPORTAGE

TORQUE SPECIFICATIONS (SPORTAGE)