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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. (Refer to SAFETY PRECAUTION ) .

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. (Refer to HIGH VOLTAGE SHUT-OFF PROCEDURE ).

  1. Shut off the high voltage circuit.

    Refer to HIGH VOLTAGE SHUT-OFF PROCEDURE .

  2. Remove the under cover (A).

    Tightening torque: 

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

    Fig 1: Under Cover
    G08308014Courtesy of KIA MOTORS AMERICA, INC.
  3. Drain the coolant of hybrid motor cooling system.

    (Refer to "COOLANT ")

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

    (Refer to "COOLANT ")

  5. Remove the hybrid power control unit assembly.

    (Refer to "HPCU (HYBRID POWER CONTROL UNIT) ")

  6. Remove the duct (A).

    Tightening torque: 

    7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

    Fig 2: Air Duct
    G00569668Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the air cleaner assembly.
    1. Disconnect the breather hose (A).
    2. Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).

      3. Tightening torque  :

      Hose clamp bolt:

      2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)

      Air cleaner assembly bolts:

      7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

    Fig 3: Breather Hose, Air Intake Hose & Air Cleaner Assembly
    G08312310Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When installing the air intake hose, the plate of the hose clamp must be in line with the stopper of the hose.
    • When installing the air intake hose, the center of the mark of hose must be in line with the throttle body rib.
      • Fig 4: Air Intake Hose Installation Position
      G08312311Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the hybrid power control unit (HPCU) tray (A).

    Tightening torque  :

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

    Fig 5: Hybrid Power Control Unit Tray
    G08308000Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove heater hose pump (A).
    Fig 6: Heater Hose Pump
    G00569669Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the solenoid valve connector (B) and inhibitor switch connector (A).
    Fig 7: Solenoid Valve Connector & Inhibitor Switch Connector
    G08308002Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the resolver sensor connector (A) and then remove the wiring bracket (B, C).
    Fig 8: Resolver Sensor Connector & Wiring Brackets
    G00547240Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the motor connector (A).
    Fig 9: Removing Motor Connector
    G00547241Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the electric oil pump (EOP) connector (A).
    Fig 10: Electric Oil Pump Connector
    G08308003Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the shift cable (C) after removing the nut (A) and the bolt (B).
    Fig 11: Shift Cable, Nut & Bolt
    G08308004Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the ground line after removing the bolt (A).
    Fig 12: Ground Line Bolt
    G08308006Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the ATF warmer hose (A).
    Fig 13: ATF Warmer Hose
    G08308007Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the automatic transaxle upper mounting bolt (A-2ea).

    Tightening torque  :

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

    Fig 14: Automatic Transaxle Upper Mounting Bolts
    G08308013Courtesy of KIA MOTORS AMERICA, INC.
  18. Assemble the engine support fixture.

    (Refer to "SPECIAL SERVICE TOOLS ")

  19. Using the engine support fixture, hold the engine and transaxle assembly safely.
    Fig 15: Engine Support Fixture
    G08308008Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the cover (A).
    Fig 16: Cover
    G08308009Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the automatic 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)

    Fig 17: Automatic Transaxle Support Bracket Mounting Bolts
    G08308010Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the automatic transaxle support bracket (A).

    Tightening torque  :

    58.8 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

    Fig 18: Automatic Transaxle Mounting Support Bracket
    G08308011Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the electric oil pump (EOP) connector (A) and clips (B).
  24. Remove the clutch pressure sensor (CPS) connector (C).
    Fig 19: Electric Oil Pump Connector, Clips & Clutch Pressure Sensor Connector
    G08308015Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the Drive shaft assembly.

    (Refer to "FRONT DRIVESHAFT ")

  26. Remove the Sub frame assembly.

    (Refer to "FRONT CROSS MEMBER ")

  27. Remove the heat protector (A).

    Tightening torque: 

    Transaxle side : 11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)

    Engine side : 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

    Fig 20: Heat Protector Bolts
    G00547242Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the mounting bolts (A, B) after supporting the transaxle by a jack.

    Tightening torque: 

    (A) 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

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

    Fig 21: Transaxle Mounting Bolts
    G00547243Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the transaxle while slowly lowering the jack.
    NOTE:

    Be careful not to damage other system or parts when removing the transaxle assembly.

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