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Home >> Kia >> 2009 >> Optima EX, 2.4 3 >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Engine And Transaxle Assembly - 2.4L >> Engine And Transaxle Assembly >> Repair Procedures >> Removal
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Repair Procedures: Removal

CAUTION:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE: Mark all wiring and hoses to avoid misconnection.
  1. Disconnect the battery terminals and remove the battery.
  2. Remove the engine cover (A).
    Fig 1: Identifying Engine Cover
    G06361576Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the air duct (A).
    Fig 2: Identifying Air Duct
    G06361577Courtesy of KIA MOTORS AMERICA, INC.
  4. Disconnect the breather hose (A), ECM connector (B) and remove the air cleaner assembly (C).

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

    Fig 3: Identifying Breather Hose, ECM Connector And Air Cleaner Assembly
    G06361578Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the front wheels.

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

  6. Remove the under cover (A).

    Tightening torque :  8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)

    Fig 4: Identifying Under Cover
    G06361579Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the drain plug and drain the engine coolant.
  8. Remove the radiator upper hose (A) and lower hose (B).
    Fig 5: Identifying Radiator Upper Hose And Lower Hose
    G06361580Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the heater hoses (A).
    Fig 6: Identifying Heater Hoses
    G06361581Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the VIS connector (A), OPS connector (B), knock sensor connector (C) and A/C switch connector (D).
    Fig 7: Identifying VIS Connector, OPS Connector, Knock Sensor Connector And A/C Switch Connector
    G06361582Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the intake OCV connector (A).
    Fig 8: Identifying Intake OCV Connector
    G06361583Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the injector connectors (A) and ignition coil connectors (B).
    Fig 9: Identifying Injector Connectors And Ignition Coil Connectors
    G06361584Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the ETC connector (A) and MAP sensor connector (B).
    Fig 10: Identifying ETC Connector And MAP Sensor Connector
    G06361585Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect the CMP sensor connector (A) and fuel hose (B).
    Fig 11: Identifying CMP Sensor Connector And Fuel Hose
    G06361586Courtesy of KIA MOTORS AMERICA, INC.
  15. Disconnect the PCSV connector (A), ECT connector (B), condenser connector (C), CKP sensor connector (D), CMP sensor connector (E) and brake booster vacuum hose (F).
    Fig 12: Identifying PCSV Connector, ECT Connector, Condenser Connector, CKP Sensor Connector And CMP Sensor Connector
    G06361587Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the alternator connector (A), and 'B' terminal cable (B).
    Fig 13: Identifying Alternator Connector And 'B' Terminal Cable
    G06361588Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the starter connector (A), and cable (B).
    Fig 14: Identifying Starter Connector And Cable
    G06361589Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the exhaust OCV connector (A).
    Fig 15: Identifying Exhaust OCV Connector
    G06361590Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the power steering oil hose (A).
    Fig 16: Identifying Power Steering Oil Hose
    G06361591Courtesy of KIA MOTORS AMERICA, INC.
  20. Disconnect the transaxle control cable and wiring connectors. (Refer to MANUAL TRANSAXLE SYSTEM or AUTOMATIC TRANSAXLE SYSTEM )
  21. Recover refrigerant and remove the high & low pressure pipe. (Refer toREFRIGERANT LINE )
  22. Disconnect the EPS connector (A).
    Fig 17: Identifying EPS Connector
    G06361592Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the lower arm (B) & fork (A) mounting bolt (C). (Refer to FRONT SUSPENSION SYSTEM )

    Tightening torque :  137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

    Fig 18: Identifying Lower Arm And Fork Mounting Bolt
    G06361593Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the lower arm ball joint mounting bolts (A). (Refer to FRONT SUSPENSION SYSTEM )

    Tightening torque :  98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

    Fig 19: Identifying Lower Arm Ball Joint Mounting Bolts
    G06361594Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the stabilizer bar link mounting nut (A). (Refer to FRONT SUSPENSION SYSTEM )

    Tightening torque :  98.1 ~ 117.7N.m (10.0 ~ 12.0kgf.m, 72.3 ~ 86.8lb-ft)

    Fig 20: Identifying Stabilizer Bar Link Mounting Nut
    G06361595Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle. (Refer to GENERAL INFORMATION (STEERING SYSTEM) )

    Tightening torque :  23.5 ~ 33.3N.m (2.4 ~ 3.4kgf.m, 17.4 ~ 24.6lb-ft)

    Fig 21: Identifying Tie Rod End With Knuckle
    G06361596Courtesy of KIA MOTORS AMERICA, INC.
  27. Disconnect the driveshaft form the axle hub.
  28. Remove power steering return hose (A) and drain power steering oil.
    Fig 22: Identifying Power Steering Return Hose
    G06361597Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove steering u-joint mounting bolt (A). (Refer to STEERING COLUMN & SHAFT )

    Tightening torque :  17.7 ~ 24.5N.m (1.8 ~ 2.5kgf.m, 13.0 ~ 18.1lb-ft)

    Fig 23: Identifying Steering U-Joint Mounting Bolt
    G06361598Courtesy of KIA MOTORS AMERICA, INC.
  30. Disconnect the O2 sensor connector (A) and remove the front muffler (B).

    Tightening torque :  39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lb-ft)

    Fig 24: Identifying O2 Sensor Connector And Front Muffler
    G06361599Courtesy of KIA MOTORS AMERICA, INC.
  31. Support the sub frame (A) with a floor jack then remove the stay (B) and sub frame mounting bolts.

    Tightening torque :  137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)

    Fig 25: Identifying Sub Frame
    G06361600Courtesy of KIA MOTORS AMERICA, INC.

    Tightening torque :  44.1 ~ 58.8N.m (4.5 ~ 6.0kgf.m, 32.5 ~ 43.4lb-ft)

    Fig 26: Identifying Stay
    G06361601Courtesy of KIA MOTORS AMERICA, INC.
  32. Disconnect the ground line and remove the engine mounting bracket (A).

    Tightening torque :  63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

    Fig 27: Identifying Sub Frame Location
    G06361602Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the transaxle mounting bracket bolt (A).

    Tightening torque :  63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

    Fig 28: Identifying Transaxle Mounting Bracket Bolt
    G06361603Courtesy of KIA MOTORS AMERICA, INC.
  34. Lift up the vehicle and remove the engine and transaxle assembly from the vehicle.
    CAUTION: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
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