Kia Optima DL3: Engine And Transaxle Assembly / Engine And Transaxle Assembly

Kia Optima DL3 2019-2025 Service and Repair 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.
  
•

Mark all wiring and hoses to avoid misconnection.

•

For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. And then turn off the ignition switch after engine stops.
1.

Remove the engine cover.

(Refer to Engine and Transaxle Assembly - "Engine Cover")

2.

Disconnect the battery negative terminal.
3.

Remove the battery and battery tray.

(Refer to Engine Electrical System - "Battery")

4.

Remove the air cleaner assembly.

(Refer to Intake and Exhaust System - "Air Cleaner")

5.

Remove the engine room under cover.

(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

6.

Drain the engine coolant.

(Refer to Cooling System - "Coolant")

7.

Disconnect the radiator upper hose (A).
8.

Disconnect the radiator lower hose (A).
9.

Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

(Refer to Heating, Ventilation Air conditioning - "Compressor")

10.

Disconnect the wire harness connectors, control cables and ATF cooler hoses (A/T only) from the transaxle.

(Refer to Automatic Transaxle System - "Automatic transaxle")

11.

Disconnect the heater hose (A).
12.

Disconnect the brake booster vacuum hose (A).
13.

Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
14.

Remove the wiring harness from the engine room.

(1)

Disconnect the fuse box main wiring connectors (A).

(2)

Disconnect the fuse box wiring cable (A), and then remove the main wiring protector (B).

Tightening torque :

7.8 - 9.8 N•m (0.8 - 1.0 kgf•m , 5.7 - 7.2 lb•ft)

15.

Remove the front muffler.

(Refer to Intake and Exhaust System - "Muffler")

16.

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)

Bolts (C) :

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

  

Do not reuse the bolt C, which is special bolt coated with bond.

17.

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)

18.

Remove the sub frame.

(Refer to Suspension system - "Sub Frame")

19.

Support the engine and transaxle assembly with a lift table.
20.

Disconnect the engine ground cable.

Tightening torque :

10.8 - 13.7 N•m (1.1 - 1.4 kgf•m, 8.0 - 10.1 lb•ft)
21.

Remove the engine mounting support bracket (A).

Tightening torque :

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

22.

Disconnect the transaxle ground line (A).
23.

Remove the mounting side pannel packing (A).

24.

Remove the transaxle mounting bolts (A).

Tightening torque :

107.8 - 127.4 N•m (11.0 - 13.0 kgf•m , 79.5 - 94.0 lb•ft)

25.

Remove the engine and transaxle assembly (A) by lifting vehicle.

  
•

Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.

•

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.

Perform the following :

•

Refill engine with engine oil.

•

Refill transaxle with fluid.

•

Refill radiator and reservoir tank with engine coolant.
•

Place heater control knob on "HOT" position.

•

Bleed air from the 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.

•

Clean battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.

•

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.

    Components and components location Components 1. Transaxle mounting bracket 2. Roll rod bracket 3. Engine mounting bracket 4.

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