Repair procedures: Removal

WARNING: The hybrid system uses DC 270V high voltage. So, be sure to follow safety instructions below. Otherwise, there may be a serious injury or electrocution (Refer to SAFETY PRECAUTION .

Remove the following items;
1. Engine cover (A).
2. Air cleaner assembly and air duct (B). (Refer to INTAKE MANIFOLD .
3. Remove the Hybrid Power Control Unit (HPCU) assembly (C).
(Refer to "HYBRID CONTROL SYSTEM " in HC group.)

Fig 1: Identifying Engine Cover, Hybrid Power Control Unit Assembly, Air Cleaner Assembly And Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Hybrid Power Control Unit (HPCU) tray (A).
Tightening torque:

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

Fig 2: Locating Hybrid Power Control Unit Tray
Courtesy of KIA MOTORS AMERICA, INC.
Remove heater hose pump (A).

Fig 3: Locating Heater Hose Pump
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the solenoid valve connector (A) and inhibitor switch connector (B).

Fig 4: Locating Solenoid Valve Connector And Inhibitor Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the Electric Oil Pump (EOP) connector (A).

Fig 5: Locating Electric Oil Pump Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift cable (C) after removing the nut (A) and the bolt (B).
Tightening torque:
1. 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
2. 14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)
  
  Fig 6: Locating Shift Cable, Nut And Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the motor connector (A).

Fig 7: Locating Motor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ground line after removing the bolt (A).

Fig 8: Locating Ground Line Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ATF warmer hose (A).

Fig 9: Locating ATF Warmer Hose
Courtesy of KIA MOTORS AMERICA, INC.
Using the engine support fixture (Support sst No.: 09200-38001) hold the engine and adapter.

Fig 10: Identifying Engine Support Fixture (Support SST No - 09200-38001)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cover (A).

Fig 11: Locating Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the automatic transaxle support bracket mounting bolt (A).
Tightening torque:

88.2 ~ 107.8 N.m (9.0 ~ 11.0 Kgf.m, 65 ~ 79.5 lb-ft)

Fig 12: Locating Automatic Transaxle Support Bracket Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the automatic transaxle mounting support bracket (A).
Tightening torque:
1. 58.8 ~ 78.4 N.m (6.0 ~ 8.0 kgf.m, 43.3 ~ 57.8 lb-ft)
  
  Fig 13: Locating Automatic Transaxle Mounting Support Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the sensor connector (A) and (B).

Fig 14: Locating Sensor Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Remove the automatic transaxle upper mounting bolt (A-2ea).
Tightening torque:
1. 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
Fig 15: Locating Automatic Transaxle Upper Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the under cover (A).
Tightening torque:

7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)

Fig 16: Locating Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Electric Oil Pump (EOP) connector (A) and clips (B).
Remove the Clutch Pressure Sensor (CPS) connector (C).

Fig 17: Locating Electric Oil Pump Connector, Clips And Clutch Pressure Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the following items;
1. Sub frame assembly.
  (Refer to "FRONT SUSPENSION " in SS group.)
2. Drive shaft assembly.
(Refer to "FRONT DRIVESHAFT " in DS group.)
Remove the drive shaft cover (A).

Fig 18: Locating Drive Shaft Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the automatic transaxle with a jack after removing the mounting bolt (A-5ea).
Tightening torque:
1. 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)
  
  Fig 19: Locating Automatic Transaxle Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.