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Home >> Kia >> 2016 >> Optima SX Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 84 (Engine & Transaxle Assembly (R & I) - 1.6L - Optima (Except HEV)) >> Engine And Transmission Assembly >> Repair Procedures >> Removal

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.
  • 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.

Information 

Mark all wiring and hoses to avoid misconnection.

  1. Remove the engine cover.

    (Refer to Engine and Transmission Assembly - "ENGINE COVER ")

  2. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  3. Remove the engine control module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  4. Remove the battery tray.

    (Refer to Engine Electrical System - "BATTERY ")

  5. Remove the air duct and air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  6. Remove the engine room under cover.

    (Refer to Engine and Transmission Assembly - "ENGINE ROOM UNDER COVER ")

  7. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  8. Remove the intercooler inlet hoses & pipe (A).

    Tightening torque 

    Bolts:

    19.6 - 26.4 N.m (2.0 - 2.7 kgf.m, 14.4 - 19.5 lb.ft)

    Clamp:

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 1: Removing Intercooler Inlet Hoses And Pipe
    G11823015Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the RCV solenoid valve hose (A), radiator upper hose (B) and intercooler outlet hose (C).

    Tightening torque: 

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 2: Locating RCV Solenoid Valve Hose, Radiator Upper Hose And Intercooler Outlet Hose
    G11823016Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the radiator lower hose (A).
    Fig 3: Locating Radiator Lower Hose
    G11823017Courtesy of KIA MOTORS AMERICA, INC.
  11. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.

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

  12. Remove the double clutch transmission wiring harness connectors and control cable from the transaxle.

    (Refer to Dual Clutch Transmission (DCT) - "DUAL CLUTCH TRANSMISSION ASSEMBLY ")

  13. Disconnect the brake booster vacuum hose (A).
    Fig 4: Locating Brake Booster Vacuum Hose
    G11823018Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect the heater hose (A).
    Fig 5: Locating Heater Hose
    G11823019Courtesy of KIA MOTORS AMERICA, INC.
  15. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
    Fig 6: Locating Fuel Hose And Purge Control Solenoid Valve Hose
    G11823020Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the engine wiring.
    1. Disconnect the fuse box wiring cable (A).
    2. Remove the battery wiring protector (B).
      Fig 7: Locating Fuse Box Wiring Cable And Battery Wiring Protector
      G11823021Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the fuse box main wiring connector (A).
      Fig 8: Locating Fuse Box Main Wiring Connector
      G11823022Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the ECM connector (A).
    5. Remove the ground cable (B).

      Tightening torque: 

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

    6. Remove the main wiring protector (C).
    Fig 9: Locating ECM Connector, Ground Cable And Main Wiring Protector
    G11823023Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the front muffler.

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

  18. 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)

    Fig 10: Removing Roll Rod Bracket
    G11823024Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use a new bolt (B).
  19. 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 11: Removing Roll Rod Mounting Support Bracket
    G11823025Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the sub frame.

    (Refer to Suspension system - "SUB FRAME ")

  21. Support the engine and transaxle assembly with a lift table.
  22. 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)

    Fig 12: Removing Engine Ground Cable
    G11823026Courtesy of KIA MOTORS AMERICA, INC.
  23. 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)

    Fig 13: Removing Engine Mounting Support Bracket
    G11823027Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Do not reuse the nut.
  24. Remove the service cover (A).
    Fig 14: Locating Service Cover
    G11823028Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the double clutch transmission mounting bolts (A).

    Tightening torque: 

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

    Fig 15: Removing Double Clutch Transmission Mounting Bolts
    G11823029Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use a new bolts.
  26. Remove the engine and transmission assembly (A) by lifting vehicle.
Fig 16: Lifting Vehicle
G11823030Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
  • Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
  • When removing the engine and transmission assembly, be careful not to damage any surrounding parts or body components.
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