Engine & Transaxle Assembly - Hev: Removal & Installation Kia Optima III

Removal

Note. Mark all wiring and hoses to avoid misconnection. 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.

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1. Shut off the High Voltage circuit (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535721-S38559203892013031200000) .
2. Remove the engine cover (A).
3. Remove the air duct (A). Tightening torque: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
4. Remove the air cleaner assembly. Disconnect the breather hose (A). 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) NOTE: 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.
5. Remove the under covers (A, B). Tightening torque: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) NOTE: 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 «ENGINE COOLING SYSTEM - HEV»(ref-535726)
7. Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to " «COOLANT»(ref-535713-S34995588842013031200000) .
8. Disconnect the radiator upper hose (A) and lower hose (B).
9. Remove the HPCU (Hybrid power control unit). (Refer to " «HPCU (HYBRID POWER CONTROL UNIT)»(ref-535714-S41751298682013031200000) ")
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 " «ELECTRIC AC COMPRESSOR»(ref-535715-S31575252822013031200000) ")
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 HSG (Hybrid starter generator) (A) and EWP (Electric water pump) (B).
14. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) .
15. Disconnect the heater hoses (A).
16. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
17. Remove the front muffler (A).
18. Remove the steering u-joint mounting bolt (A). (Refer to «STEERING COLUMN AND SHAFT»(ref-535717-S12798084992013031200000) )
19. Remove the front wheels. (Refer to " «WHEEL»(ref-535718-S09157268762013031200000) ")
20. Remove the lower arms (A). (Refer to " «FRONT LOWER ARM»(ref-535719-S00319031552013031200000) ")
21. Remove the stabilizer bar links (A). (Refer to " «FRONT STABILIZER BAR»(ref-535719-S13641366802013031200000) ")
22. Remove the tie rod ends (A). (Refer to " «STEERING GEAR BOX»(ref-535717-S14910243942013031200000) ")
23. Disconnect the drive shafts (A) from the axle hubs. (Refer to " «FRONT HUB KNUCKLE»(ref-535720-S06416839362013031200000) ")
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 " «FRONT CROSS MEMBER»(ref-535719-S01449993182013031200000) ") 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) NOTE: 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, and then disconnect the ground line (A) and remove the engine mounting support bracket (B). Tightening torque: 78.4 ~ 98.0 N.m (8.0 ~ 10.0 kgf.m, 57.6 ~ 72.0 lb-ft)
28. Disconnect the ground line (A).
29. Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A). Tightening torque: 88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
30. Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle. CAUTION: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Note. Mark all wiring and hoses to avoid misconnection. 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.

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1. Shut off the High Voltage circuit (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535721-S38559203892013031200000) .
2. Remove the engine cover (A).
3. Remove the air duct (A). Tightening torque: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
4. Remove the air cleaner assembly. Disconnect the breather hose (A). 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) NOTE: 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.
5. Remove the under covers (A, B). Tightening torque: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) NOTE: 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 «ENGINE COOLING SYSTEM - HEV»(ref-535726)
7. Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to " «COOLANT»(ref-535713-S34995588842013031200000) ")
8. Disconnect the radiator upper hose (A) and lower hose (B).
9. Remove the HPCU (Hybrid power control unit). (Refer to " «HPCU (HYBRID POWER CONTROL UNIT)»(ref-535714-S41751298682013031200000) ")
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 " «ELECTRIC AC COMPRESSOR»(ref-535715-S31575252822013031200000) ")
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 HSG (Hybrid starter generator) (A) and EWP (Electric water pump) (B).
14. Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to «AUTOMATIC TRANSAXLE»(ref-535716-S07341099932013031200000) .
15. Disconnect the heater hoses (A).
16. Disconnect the fuel hose (A) and the PCSV (Purge control solenoid valve) hose (B).
17. Remove the front muffler (A).
18. Remove the steering u-joint mounting bolt (A). (Refer to «STEERING COLUMN AND SHAFT»(ref-535717-S12798084992013031200000) )
19. Remove the front wheels. (Refer to " «WHEEL»(ref-535718-S09157268762013031200000) ")
20. Remove the lower arms (A). (Refer to " «FRONT LOWER ARM»(ref-535719-S00319031552013031200000) ")
21. Remove the stabilizer bar links (A). (Refer to " «FRONT STABILIZER BAR»(ref-535719-S13641366802013031200000) ")
22. Remove the tie rod ends (A). (Refer to " «STEERING GEAR BOX»(ref-535717-S14910243942013031200000) ")
23. Disconnect the drive shafts (A) from the axle hubs. (Refer to " «FRONT HUB KNUCKLE»(ref-535720-S06416839362013031200000) ")
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 " «FRONT CROSS MEMBER»(ref-535719-S01449993182013031200000) ") 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) NOTE: 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, and then disconnect the ground line (A) and remove the engine mounting support bracket (B). Tightening torque: 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
28. Disconnect the ground line (A).
29. Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A). Tightening torque: 88.2 ~ 107.8 N.m (9.0 ~ 11.0 kgf.m, 65.0 ~ 79.5 lb-ft)
30. Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle. CAUTION: 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.

Note. 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 " 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.

Note. 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).