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Home >> Kia >> 2020 >> Optima Plug-In Hybrid EX >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Block (PHEV) >> Cylinder Block >> Repair Procedures >> Disassembly

Repair Procedures: Disassembly

WARNING:
  • Be sure to read and follow the "GENERAL SAFETY INFORMATION & 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 SHUTOFF PROCEDURE " before doing any work related with the high voltage system to avoid serious electrical injuries.
NOTE:
  • Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
  • When handling a metal gasket, be careful not to fold the gasket or damage the contacting surface of the gasket.
  • To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Information 

Mark all wiring and hoses to avoid misconnection.

  1. Shut off the high voltage circuit.

    (Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT OFF PROCEDURE ")

  2. Remove the engine assembly from the vehicle.

    (Refer to Engine and Transaxle Assembly - "ENGINE AND TRANSAXLE ASSEMBLY ")

  3. Remove the transaxle assembly from the engine assembly.

    (Refer to Automatic Transaxle System - "AUTOMATIC TRANSAXLE ")

  4. Install the engine to engine stand for disassembly.
  5. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  6. Remove the exhaust manifold.

    (Refer to Intake and Exhaust System - "EXHAUST MANIFOLD ")

  7. Remove the hybrid starter generator (HSG).

    (Refer to Hybrid Motor System - "HYBRID STARTER GENERATOR (HSG) ")

  8. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  9. Remove the Cylinder head assembly.

    (Refer to Cylinder Head Assembly - "CYLINDER HEAD ")

  10. Remove the torsion damper.

    (Refer to Cylinder Block - "TORSION DAMPER) ")

  11. Remove the thermostat.

    (Refer to Cooling System - "THERMOSTAT ")

  12. Remove the electric water pump (EWP) assembly.

    (Refer to Cooling System - "ELECTRIC WATER PUMP (EWP) ")

  13. Remove the A/C compressor.

    (Refer to "REPAIR PROCEDURES ").

  14. Remove the oil filter.

    (Refer to Lubrication System - "ENGINE OIL ")

  15. Remove the oil screen.

    (Refer to Lubrication System - "OIL PAN ")

  16. Remove the piston and connecting rod assemblies.

    (Refer to Cylinder Block - "PISTON AND CONNECTING) ")

  17. Remove the Crankshaft.

    (Refer to Cylinder Block - "CRANKSHAFT) ")

  18. Remove the knock sensor.

    (Refer to Engine Control/Fuel System - "KNOCK SENSOR ")

  19. Remove the crankshaft position sensor (CKPS).

    (Refer to Engine Control/Fuel System - "CRANKSHAFT POSITION SENSOR (CKPS) ")

  20. Remove the oil pressure switch.

    (Refer to Lubrication System - "OIL PRESSURE SWITCH ")

  21. Remove the water jacket insert (A).
    G13361110Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the piston cooling oil jet (A).
    G13361111Courtesy of KIA MOTORS AMERICA, INC.
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