Hydrid Control System - Hev: Removal & Installation Kia Optima III

Removal

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

1. Shut off the High Voltage circuit (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535748-S40292040522013031200000) .
2. Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU (Refer to «COOLANT»(ref-535726-S00415111542013031200000) .
3. Remove the air cleaner assembly and duct (Refer to «INTAKE MANIFOLD»(ref-535730-S31854200232013031200000) .
4. Disconnect the coolant inlet hose (A) and outlet hose (B).
5. Remove the HPCU protector (C).
6. Disconnect the power cable (A) from the HPCU. Pull the lever (B) in the direction of the arrow with the hook (C) pressed. Press the lever (D), and then pull the power cable connector.
7. Disconnect the motor power cable (A). Pull the lever (B), and then pull the connector by rotating the lever (C).
8. Disconnect the HSG power cable (D). Pull the lever (E) in the direction of the arrow. Press the hook (F), and then pull the motor power cable connector.
9. Disconnect the electric A/C compressor power cable (A). Pull the lever (B) in the direction of the arrow. Press the hook (C), and then pull the motor power cable connector.
10. Disconnect the MCU connector (D).
11. Disconnect the HCU connector (A) and LDC connector (B).
12. Disconnect the LDC power outlet cable (C) and ground cable (D).
13. Remove the installation bolts (A), and then remove the HPCU from the vehicle.

Installation

1. Installation is reverse of removal.

HPCU installation bolt

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

LDC power outlet cable tightening bolt

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

LDC ground cable tightening bolt

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

Scheme 161

1. Refer to " «HPCU»(ref-535714-S41751298682013031200000) ".

Note. The HCU is integrated into the HPCU that can't be disassembled. So refer to " HPCU " for the removal or installation procedure of the HCU.

1. Refer to " «HPCU»(ref-535714-S41751298682013031200000) ". NOTE: The HCU is integrated into the HPCU that can't be disassembled. So refer to " «HPCU»(ref-535714-S41751298682013031200000) " for the removal or installation procedure of the HCU.
2. Perform the clutch pressure sensor calibration (Refer to " «CLUTCH PRESSURE SENSOR»(ref-535714-S05882163252013031200000) ".

1. Refer to «REMOVAL»(ref-535765-S22891470262013031200000) .

1. Refer to «INSTALLATION»(ref-535765-S07946336632013031200000) .

Scheme 162

Scheme 163

1. Shut off the High Voltage circuit (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535721-S38559203892013031200000) .
2. Remove the air cleaner assembly and duct (Refer to «REMOVAL AND INSTALLATION»(ref-535730-S16160591102013031200000) .
3. Disconnect the power cable (A) from the HPCU. Pull the lever (B) in the direction of the arrow with the hook (C) pressed. Press the lever (D), and then pull the power cable connector.
4. Remove the cover (E).
5. Remove the seal cover (A).
6. Remove the installation bolts (B), than remove the DC fuse (C) from the HPCU.

Scheme 164

1. Installation is reverse of removal.