Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

NOTE:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
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.

Information

Mark all wiring and hoses to avoid mis-connection.

WARNING:

Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage circuit according to the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries.

Shut off the High Voltage circuit (Refer to HIGH VOLTAGE SHUT-OFF PROCEDURES .)
Remove the engine cover (A).

Fig 1: Removing Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air duct (A).
Tightening torque:

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

Fig 2: Removing Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A).
2. 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)
  
  Fig 3: Disconnecting Air Intake Hose And Air Cleaner Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
  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.
  Fig 4: Installing Air Intake Hose
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the under covers (A, B).
Tightening torque:

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

Fig 5: Removing Under Covers (A, B)
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to COOLANT .)
Loosen the drain plug, and drain the inverter coolant. Remove the reservoir cap to help drain the coolant faster. (Refer to COOLANT .)
Disconnect the radiator upper hose (A) and lower hose (B).

Fig 6: Disconnecting Radiator Upper Hose And Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the hybrid power control unit (HPCU). (Refer to HPCU .)
Remove the inverter tray (A).
Tightening torque:

8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

Fig 7: Removing Inverter Tray
Courtesy of KIA MOTORS AMERICA, INC.
Recover the refrigerant and then remove the high pressure pipe (A) and low pressure pipe (B). (Refer to REFRIGERANT RECOVERY .)

Fig 8: Removing High Pressure Pipe And Low Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.
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).

Fig 9: Disconnecting ECM Connectors From ECM, Fuse Box Connector From Fuse/Relay Box And The Engine Ground Line & Wiring Protector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the cooling hoses from hybrid starter generator (HSG) (A) and electric water pump (EWP) (B).

Fig 10: Disconnecting Cooling Hoses From Hybrid Starter Generator And Electric Water Pump
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle wire harness connectors and control cable from the transaxle. (Refer to AUTOMATIC TRANSAXLE CONTROL SYSTEM - OPTIMA HEV .)
Disconnect the heater hoses (A).

Fig 11: Disconnecting Heater Hoses
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

Fig 12: Disconnecting Fuel Hose And Purge Control Solenoid Valve Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front muffler (A).

Fig 13: Removing Front Muffler
Courtesy of KIA MOTORS AMERICA, INC.
Remove the steering u-joint mounting bolt (A). (Refer to STEERING COLUMN AND SHAFT .)

Fig 14: Removing Steering U-Joint Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front wheels. (Refer to WHEEL .)
Remove the lower arms (A). (Refer to FRONT LOWER ARM .)

Fig 15: Removing Lower Arms
Courtesy of KIA MOTORS AMERICA, INC.
Remove the stabilizer bar links (A). (Refer to FRONT STABILIZER BAR .)

Fig 16: Removing Stabilizer Bar Links
Courtesy of KIA MOTORS AMERICA, INC.
Remove the tie rod ends (A). (Refer to FRONT SUSPENSION SYSTEM - OPTIMA HEV .)

Fig 17: Removing Tie Rod Ends
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the drive shafts (A) from the axle hubs. (Refer to FRONT HUB/ KNUCKLE .)

Fig 18: Disconnecting Drive Shafts From Axle Hubs
Courtesy of KIA MOTORS AMERICA, INC.
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)

Fig 19: Removing Roll Rod Bracket
Courtesy of KIA MOTORS AMERICA, INC.
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)

Fig 20: Removing Roll Rod Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts. (Refer to FRONT CROSS MEMBER .)
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)

Fig 21: Supporting Sub Frame Using Floor Jack
Courtesy of KIA MOTORS AMERICA, INC.
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.
Support the engine and transaxle assembly with a floor jack.
Disconnect the engine ground cable (A).
Tightening torque:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
Remove the engine mounting support bracket (B).
Tightening torque:

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

Fig 22: Removing Engine Mounting Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the transaxle ground line (A)

Fig 23: Disconnecting Transaxle Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Remove the automatic transaxle support bracket mounting bolt (B) after removing the cover (A)
Tightening torque:

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

Fig 24: Removing Cover (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 25: Removing Automatic Transaxle Support Bracket Mounting Bolt ((2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Lower floor jack with the engine and transaxle assembly, and then remove the engine and transaxle assembly by lifting vehicle.

Fig 26: Removing Engine And Transaxle Assembly
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.