2012 Kia Optima HybridFACTORY OEM SERVICE PROCEDURE

Repair procedures: Removal

  1. Air cleaner assembly and air duct.

    (Refer to "Intake and Exhaust system" in EM group)

  2. Remove the Hybrid Power Control Unit (HPCU) assembly.

    (Refer to "HYBRID CONTROL SYSTEM " in HC group)

  3. Remove the under cover (A).

    Tightening torque:Β 

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

    Fig 1: Locating Under Cover
    G08308091Courtesy of KIA MOTORS AMERICA, INC.
  4. Replace new gasket and the plug after draining the automatic transaxle fluid by removing the drain plug.

    (Refer to "AUTOMATIC TRANSAXLE " in this group)

  5. Remove the ATF warmer.

    (Refer to "ATF WARMER " in this group)

  6. Remove the AT tube (A) after removing eye bolt (B).

    Tightening torque:Β 

    42 ~ 48 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 31.4 lb-ft)

    Fig 2: Locating AT Tube And Eye Bolts
    G08308092Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the valve body cover (A) and breather hose clip (B).

    Tightening torque:Β 

    1. 13.8 ~ 15.7 N.m (1.4 ~ 1.6 kgf.m, 10.1 ~ 11.6 lb-ft)
    NOTE: Remove installation bolts in the engine room first and then remove others under the vehicle.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.