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

Removal

Scheme 101

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Scheme 107

1. Disconnect the 12V battery negative (-) cable.
2. Remove the air duct (A). Tightening torque: 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
3. Remove the air cleaner assembly. Disconnect the breather hose (A). 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 ~ 0.5kgf.m, 2.2 ~ 3.6 lb-ft) Air cleaner assembly bolts: 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft) 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.
4. Disconnect the TCM connector (A) and remove the room relay box cover (B).
5. Remove the resolver mounting bolt (A) and drain pipe fixed bolt (B) and then spaced the HPCU. Tightening torque : 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
6. Remove the battery (+) cable (A) after removing nut.
7. Push back the battery (+) cable (A) and then remove the TCM bracket mounting bolt (B). Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
8. Remove the TCM (A) after removing TCM bracket mounting nut. Tightening torque : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Scheme 108

Installation

1. Installation is reverse of removal. NOTE: Perform the TCM adaptive values learning procedure. (Refer to «TCM learning procedure»(ref-675082-S33020096982014121800000) ) After replacing the TCM, perform the ECM-related procedures. (Refer to «Installation»(ref-675085-S32333935472014120400000) )

Scheme 109

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Scheme 111

1. Change the shift lever to "N" range.
2. Remove the valve body assembly. (Refer to «VALVE BODY»(ref-675073-S02915867072014120400000) )
3. Disconnect the input & output speed sensor connector (A).
4. Loosen the main connector bolt (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
5. Disconnect the solenoid valve connector (A).
6. Remove the solenoid valve connector clip (B) after loosening a bolt and then remove the connector (A) by pushing it down.

1. Installation is the reverse of removal. NOTE: Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer. Perform the procedures below after installing Refill the automatic transaxle with fluid. (Refer to «FLUID»(ref-675073-S29262681622014120400000) ) Refill the engine & transaxle cooling system with coolant. (Refer to «COOLANT»(ref-675057-S24250348822014120400000) ) Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) ) Reset the automatic transaxle adaptive values using the GDS. Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.

1. Remove the valve body assembly (Refer to «VALVE BODY»(ref-675073-S02915867072014120400000) ).
2. Disconnect the input & output speed sensor connector (A).
3. Remove the input & output speed sensor (B) after removing the bolts. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Scheme 112

1. Install in the reverse order of removal.

Note. Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer. Perform the procedures below after installing Refill the automatic transaxle with fluid. (Refer to FLUID ) Refill the engine & transaxle cooling system with coolant. (Refer to COOLANT ) Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to COOLANT ) Reset the automatic transaxle adaptive values using the GDS. Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.

1. Remove the valve body assembly (Refer to «VALVE BODY»(ref-675073-S02915867072014120400000) ).
2. Disconnect the input & output speed sensor connector (A).
3. Remove the input & output speed sensor (B) after removing the bolts. Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Scheme 113

1. Install in the reverse order of removal.

Note. Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer. Perform the procedures below after installing Refill the automatic transaxle with fluid. (Refer to FLUID ) Refill the engine & transaxle cooling system with coolant. (Refer to COOLANT ) Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to COOLANT ) Reset the automatic transaxle adaptive values using the GDS. Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.

Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

Note. Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

Note. Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

Note. Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

Note. Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

Note. Replacing an on/off solenoid valve (SS-A, SS-B) does not require additional hydraulic pressure adjustment; however, the hydraulic pressure will need to be adjusted after replacing the VFS solenoid valve. If replacing the VFS solenoid valve; also replace the valve body assembly. (Refer to " VALVE BODY " )

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Scheme 119

1. 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)
2. Drain the coolant of hybrid motor cooling system. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )
3. Drain the coolant of engine & transaxle cooling system. (Refer to «COOLANT»(ref-675057-S24250348822014120400000) )
4. Remove the drain plug (A) and reinstall the drain plug after draining ATF totally. Tightening torque : 33.3 ~ 43.1 N.m (3.4 ~ 4.4 kgf.m, 24.6 ~ 31.8 lb-ft)
5. Remove the valve body wire ring fixed clip (A).
6. Remove the air duct (A).
7. Remove the air cleaner assembly. Disconnect the breather hose (A). Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).
8. Remove the hybrid power control unit (HPCU) assembly. (Refer to «REPAIR PROCEDURES»(ref-675059-S29553323622014120400000) )
9. Remove the HPCU tray (A). Tightening torque: 19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
10. Remove the automatic transaxle oil cooler tube (A). Tightening torque: Eye bolt : 41.2 ~ 47.1 N.m (4.2 ~ 4.8 kgf.m, 30.4 ~ 34.7 lb-ft) Bracket bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. Remove the valve body cover bolt after removing the ATF warmer hose (A). Tightening torque: 11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
12. Remove the solenoid valve (B) after removing the solenoid support (A).

Scheme 120

1. Installation is the reverse of removal.

Note. When installing, apply the ATF oil or White Vaseline to the O-ring (A) to prevent damage during installation.

Scheme 121

1. Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer.
2. Be careful not to damage the hose when tightening the clamp.
3. Install the clamp in the specified direction to prevent interference with surrounding components.
4. Perform the procedures below after installing

1. Refill the automatic transaxle with fluid. (Refer to «FLUID»(ref-675073-S29262681622014120400000) )
2. Refill the engine & transaxle cooling system with coolant. (Refer to «COOLANT»(ref-675057-S24250348822014120400000) )
3. Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )
4. Perform the TCM adaptive values learning procedure. (Refer to «TCM learning procedure»(ref-675082-S33020096982014121800000) )
5. Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.

1. 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)
2. Drain the coolant of hybrid motor cooling system. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )
3. Drain the coolant of engine & transaxle cooling system. (Refer to «COOLANT»(ref-675057-S24250348822014120400000) )
4. Remove the drain plug (A) and reinstall the drain plug after draining ATF totally. Tightening torque : 33.3 ~ 43.1 N.m (3.4 ~ 4.4 kgf.m, 24.6 ~ 31.8 lb-ft)
5. Remove the valve body wire ring fixed clip (A).
6. Remove the air duct (A).
7. Remove the air cleaner assembly. Disconnect the breather hose (A). Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).
8. Remove the hybrid power control unit (HPCU) assembly. (Refer to «REPAIR PROCEDURES»(ref-675059-S29553323622014120400000) )
9. Remove the HPCU tray (A). Tightening torque: 19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
10. Remove the automatic transaxle oil cooler tube (A). Tightening torque: Eye bolt : 41.2 ~ 47.1 N.m (4.2 ~ 4.8 kgf.m, 30.4 ~ 34.7 lb-ft) Bracket bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
11. Remove the valve body cover bolt after removing the ATF warmer hose (A). Tightening torque: 11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
12. Remove the solenoid valve (B) after removing the solenoid support (A).

1. Installation is the reverse of removal.

Note. When installing, apply the ATF oil or White Vaseline to the O-ring (A) to prevent damage during installation.

1. Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer.
2. Be careful not to damage the hose when tightening the clamp.
3. Install the clamp in the specified direction to prevent interference with surrounding components.
4. Perform the procedures below after installing

1. Refill the automatic transaxle with fluid. (Refer to «FLUID»(ref-675073-S29262681622014120400000) )
2. Refill the engine & transaxle cooling system with coolant. (Refer to «COOLANT»(ref-675057-S24250348822014120400000) )
3. Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )
4. Perform the TCM adaptive values learning procedure. (Refer to «TCM learning procedure»(ref-675082-S33020096982014121800000) )
5. Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.

1. Installation is the reverse of removal.

Note. Make sure that shift lever and manual control lever is "N" range before you install the shift cable. Insert securely after check the orientation of socket (A) of cable. Insert the shift cable after checking the direction of projection (B) to prevent wrong assembly.

Scheme 122

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Scheme 125

Scheme 126

1. Remove the screw and then remove the "P" position switch (A).
2. Remove the plastic bracket (A) and remove the shift lock solenoid (B).
3. Remove the main connector (C).
4. Loosen the screw and remove the manual mode switch housing (A).
5. Remove the wiring fixed bracket (A) of main connector.
6. Remove the wiring of "P" position switch from the main connector. NOTE: Check the wiring color before disconnecting the wiring.

Scheme 127

1. Loosen the screw and remove the "P" position switch (A).
2. Remove the plastic bracket (A) and remove the shift lock solenoid (B).
3. Remove the main connector (C).
4. Loosen the screw and remove the manual mode switch housing (A).
5. Remove the wiring fixed bracket (A) of main connector.
6. Remove the wiring of shift lock solenoid from the main connector. NOTE: Check the wiring color before disconnecting the wiring.

Scheme 128

1. Loosen the screw and remove the "P" position switch (A).
2. Remove the plastic bracket (A) and remove the shift lock solenoid (B).
3. Remove the main connector (C).
4. Loosen the screw and remove the manual mode switch housing (A).
5. Remove the wiring fixed bracket (A) of main connector.
6. Remove the wiring of manual mode switch housing from the main connector. NOTE: Check the wiring color before disconnecting the wiring.

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Scheme 131

1. Shut off the high voltage circuit. (Refer to «HIGH VOLTAGE SHUT-OFF PROCEDURE»(ref-675050-S21464474132014120400000) )
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)
3. Drain the coolant of hybrid motor cooling system. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )
4. Remove the air duct (A). Tightening torque: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
5. Remove the air cleaner assembly. Disconnect the breather hose (A). 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) 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.
6. Remove the hybrid power control unit assembly. (Refer to «REPAIR PROCEDURES»(ref-675059-S29553323622014120400000) )
7. Remove the hybrid power control unit tray (A). Tightening torque: 19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)
8. Loosen the nut (A) and then remove the shift cable (B). Tightening torque: 9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)
9. Remove pull the arrow direction knob (A) after removing the boots from console upper cover (B).
10. Remove the floor console assembly. (Refer to «CONSOLE»(ref-675054-S24429339762014120400000) )
11. Disconnect the shift cable (A) from the shift lever.
12. Loosen the nut (B) and remove the cable retainer (A). Tightening torque: 9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.9 lb-ft)
13. Remove the shift cable by pulling it toward the interior.

Scheme 132

1. Install in the reverse order of removal. NOTE: Make sure that shift lever and manual control lever is "N" range before you install the shift cable. Insert securely after check the orientation of socket (A) of cable. Insert the shift cable after checking the direction of projection (B) to prevent wrong assembly. Tighten the nut to specified torque after removing free play by pushing "F"direction When installing the shift cable at transaxle side. Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to «COOLANT»(ref-675058-S26752267332014120400000) )