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.

Shut off the high voltage circuit.
(Refer to HIGH VOLTAGE SHUT-OFF PROCEDURES .)
Remove the under cover (A).
Tightening torque:

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

Fig 1: Removing Automatic Transaxle System Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Drain the coolant of hybrid motor cooling system.
(Refer to COOLANT .)
Drain the coolant of engine & transaxle cooling system.
(Refer to COOLANT .)
Remove the hybrid power control unit assembly.
(Refer to HPCU (HYBRID POWER CONTROL UNIT) .)
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: Removing Automatic Transaxle System Duct
Courtesy of KIA MOTORS AMERICA, INC.
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).
  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: Disconnecting Air Intake Hose And Air Cleaner Assembly
  Courtesy 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: Installing Air Intake Hose
  Courtesy of KIA MOTORS AMERICA, INC.
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: Removing Hybrid Power Control Unit (HPCU) Tray
Courtesy of KIA MOTORS AMERICA, INC.
Remove heater hose pump (A).

Fig 6: Removing Heater Hose Pump
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the solenoid valve connector (B) and inhibitor switch connector (A).

Fig 7: Disconnecting Solenoid Valve And Inhibitor Switch Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the resolver sensor connector (A) and then remove the wiring bracket (B, C).

Fig 8: Disconnecting Resolver Sensor Connector And Wiring Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the motor connector (A).

Fig 9: Removing Motor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the electric oil pump (EOP) connector (A).

Fig 10: Removing 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. 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, 10.8 ~ 15.9 lb-ft)
Fig 11: Removing Shift Cable, Nut And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ground line after removing the bolt (A).

Fig 12: Removing Ground Line And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the ATF warmer hose (A).

Fig 13: Removing ATF Warmer Hose
Courtesy of KIA MOTORS AMERICA, INC.
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: Removing Automatic Transaxle Upper Mounting Bolt (A-2EA)
Courtesy of KIA MOTORS AMERICA, INC.
Assemble the engine support fixture.
(Refer to SPECIAL SERVICE TOOLS .)
Using the engine support fixture, hold the engine and transaxle assembly safely.

Fig 15: Supporting Engine And Transaxle Assembly Safely Using Engine Support Fixture
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cover (A).

Fig 16: Removing Engine And Transaxle Assembly Cover
Courtesy of KIA MOTORS AMERICA, INC.
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: Removing Automatic Transaxle Mounting Bracket Bolts
Courtesy of KIA MOTORS AMERICA, INC.
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: Removing Automatic Transaxle Support Bracket
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 19: Removing Clutch Pressure Sensor Connector, Electric Oil Pump Connector And Clips
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Drive shaft assembly.
(Refer to DRIVESHAFT ASSEMBLY - OPTIMA HEV .)
Remove the Sub frame assembly.
(Refer to FRONT SUSPENSION SYSTEM - OPTIMA HEV .)
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: Removing Heat Protector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the mounting bolts (A, B) after supporting the transaxle by a jack.
Tightening torque:
1. 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)
2. 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
Fig 21: Removing Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the transaxle while slowly lower the jack.
NOTE: Be careful not to damage other system or parts when removing the transaxle assembly.