Automatic Transaxle System - Hev: Removal & Installation Kia Optima III

Removal

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1. Remove the following items; Engine cover (A). Air cleaner assembly and air duct (B). (Refer to «INTAKE MANIFOLD»(/kia/optima/iii-2010-2013/remont/exhaust/#intake-exhaust-system-hev) . Remove the Hybrid Power Control Unit (HPCU) assembly (C). (Refer to " «HYBRID CONTROL SYSTEM»(ref-535721-S23921223772013031200000) " in HC group.)
2. 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)
3. Remove heater hose pump (A).
4. Disconnect the solenoid valve connector (A) and inhibitor switch connector (B).
5. Disconnect the Electric Oil Pump (EOP) connector (A).
6. Remove the shift cable (C) after removing the nut (A) and the bolt (B). Tightening torque: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft) 14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)
7. Disconnect the motor connector (A).
8. Remove the ground line after removing the bolt (A).
9. Remove the ATF warmer hose (A).
10. Using the engine support fixture (Support sst No.: 09200-38001) hold the engine and adapter.
11. Remove the cover (A).
12. 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)
13. Remove the automatic transaxle mounting support bracket (A). Tightening torque: 58.8 ~ 78.4 N.m (6.0 ~ 8.0 kgf.m, 43.3 ~ 57.8 lb-ft)
14. Remove the sensor connector (A) and (B).
15. Remove the automatic transaxle upper mounting bolt (A-2ea). Tightening torque: 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
16. 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)
17. Remove the Electric Oil Pump (EOP) connector (A) and clips (B).
18. Remove the Clutch Pressure Sensor (CPS) connector (C).
19. Remove the following items; Sub frame assembly. (Refer to " «FRONT SUSPENSION»(ref-535746-S02597370202013031200000) " in SS group.) Drive shaft assembly. (Refer to " «FRONT DRIVESHAFT»(ref-535747-S33783739682013031200000) " in DS group.)
20. Remove the drive shaft cover (A).
21. Remove the automatic transaxle with a jack after removing the mounting bolt (A-5ea). Tightening torque: 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

Installation

1. Installation is the reverse of removal.

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Note. After replacement or reinstallation procedure of the automatic transaxle assembly, must perform procedures below. Power steering fluid replacement and air bleeding. (Refer to "General information" in ST group) Add automatic transaxle fluid as needed. (Refer to FLUID . After servicing the automatic transaxle or TCM, clear the diagnostic trouble codes (DTC) using the GDS tool. Diagnostic trouble codes (DTC) cannot be cleared by disconnecting the battery. When replacing the automatic transaxle and TCM, erase the diagnostic trouble code by using GDS. When deleting diagnostic trouble code, use the GDS as possible. When replacing the automatic transaxle, reset the automatic transaxle's values by using GDS. Perform TCM learning after replacing the transaxle to prevent slow transaxle response, jerky acceleration and jerky startup. (Refer to " AUTOMATIC TRANSAXLE " in this group)

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1. Bleed air from the hybrid motor cooling system using GDS. (Refer to " «HYBRID MOTOR»(ref-535748-S34345584332013031200000) " in HM group)
2. Resolver sensor calibration (Refer to " «RESOLVER SENSOR»(ref-535748-S16300562552013031200000) )" in HM group)
3. Clutch pressure sensor calibration (Refer to "Hybrid control system ( «CLUTCH PRESSURE SENSOR (CPS)»(ref-535721-S34357463882013031200000) )" in HC group) NOTE: HCU need to be learnt the kissing point at both ends of the clutch to reduce shock while engine power is connected the transaxle. So perform the Clutch Pressure Sensor Calibration after installing the CPS, HCU, engine or hybrid drive motor.

See also:
• INTAKE MANIFOLD