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Home › Kia › 2020 › Optima Hybrid EX › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle System (HEV) › Repair Procedures › Removal

Repair Procedures: Removal

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.
  1. Shut off the high voltage circuit.

    (Refer to Automatic Transaxle System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")

  2. Remove the under cover.

    (Refer to Engine Mechanical System - "ENGINE ROOM UNDER COVER ")

  3. Drain the coolant of engine & transaxle cooling system.

    (Refer to Engine Mechanical System - "COOLANT ")

  4. Drain the coolant of hybrid motor cooling system.

    (Refer to Hybrid Motor System - " COOLANT ")

  5. Remove the air cleaner assembly and air duct.

    (Refer to Engine Mechanical System - "AIR CLEANER ")

  6. Remove the hybrid power control unit (HPCU) assembly.

    (Refer to Hybrid Control System - "HYBRID POWER CONTROL UNIT ")

  7. Remove the high voltage cable (A) and HPCU tray (B).

    Tightening torque: 

    19.6 - 29.4 N.m (2.0 - 3.0 kgf.m, 14.5 - 21.7 lb.ft)

    G13388508Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the solenoid valve connector (A) and inhibitor switch connector (B) and then remove the wiring from the bracket (C).
    G13388509Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the shift cable (C) after loosening the nut (A) and bolts (B).

    Tightening torque: 

    1. 9.8 - 14.7 N.m (1.0 - 1.5 kgf.m, 7.2 - 10.8 lb.ft)
    2. 14.7 - 21.6 N.m (1.5 - 2.2 kgf.m, 10.9 - 15.9 lb.ft)
    G13388510Courtesy of KIA MOTORS AMERICA, INC.
  10. Loosen the ground bolt (A).
    G13388511Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the hybrid drive motor high voltage connector (A).
    G13388512Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the electric oil pump (EOP) connector (A).
    G13388513Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the engine clutch pressure sensor connector (A).
    G13388514Courtesy of KIA MOTORS AMERICA, INC.
  14. Loosen the heat protector mounting bolt (A).
    G13388515Courtesy of KIA MOTORS AMERICA, INC.
  15. Separate the ATF warmer hose (A).
    G13388516Courtesy of KIA MOTORS AMERICA, INC.
  16. Loosen the transaxle upper mounting bolts (A).

    Tightening torque: 

    42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb.ft)

    G13388517Courtesy of KIA MOTORS AMERICA, INC.
  17. Assemble the engine support fixture on the engine room.

    (Refer to Special Service Tools - "ENGINE SUPPORT FIXTURE ASSEMBLY DRAWING ")

    G13388518Courtesy of KIA MOTORS AMERICA, INC.
  18. Support the transaxle on a jack.
    G13388519Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the cover (A).
    G13388520Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the transaxle mounting bracket bolts (A).

    Tightening torque: 

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

    G13388521Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the transaxle support bracket (A).

    Tightening torque: 

    58.9 - 78.5 N.m (6.0 - 8.0 kgf.m, 43.4 - 57.9 lb.ft)

    G13388522Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the sub frame.

    (Refer to Suspension System - "SUB FRAME ")

  23. Remove the drive shaft assembly.

    (Refer to Driveshaft and Axle - "FRONT DRIVESHAFT ")

  24. Remove the wiring fixing clip (A) from the valve body.
    G13388523Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the resolver & temperature sensor connector (A).
    G13388524Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the electric oil pump (EOP) connector (A) and mounting clip (B).
    G13388525Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: How to disconnect the connector
    1. Pull the it while pushing hook (B) after releasing the lock pulling the lever (A).
      G13388526Courtesy of KIA MOTORS AMERICA, INC.
    2. Pull the connector while raise the hook (C) using driver.
      G13388527Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the roll rod support bracket (A).

    Tightening torque: 

    49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb.ft

    G13388528Courtesy of KIA MOTORS AMERICA, INC.
  28. Loosen the transaxle lower mounting bolts (A, B) after supporting the transaxle safely on a jack.

    Tightening torque: 

    1. 42.2 - 54.0 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb.ft)
    2. 42.2 - 48.1 N.m (4.3 - 4.9 kgf.m, 31.1 - 35.4 lb.ft)
      G13388529Courtesy of KIA MOTORS AMERICA, INC.
  29. After separating the transaxle from the engine, remove the transaxle by lowering the jack slowly.
    NOTE: Be careful not to damage other nearby systems or parts when removing the transaxle assembly.
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