2017 Kia Optima Plug-In Hybrid EXFACTORY OEM SERVICE PROCEDURE

Repair Procedures: Installation

  1. Check that the shift lever is placed in the "N" position.
  2. Install the shift cable retainer (A).

    Tightening Torque: 

    9.8 - 14.7 N.m (1.0 - 1.5 kgf.m, 7.2 - 10.8 lb.ft)

    G12347710Courtesy of KIA MOTORS AMERICA, INC.
  3. Insert the snap pin (A) after installing the shift cable.
    G12347711Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Install the shift cable after checking the direction of projection to prevent incorrect assembly.
      G12347712Courtesy of KIA MOTORS AMERICA, INC.
    • [LHD]  Mind the installation direction of snap pin and install the snap pin with the hook facing upward.
      G12347713Courtesy of KIA MOTORS AMERICA, INC.
    • [RHD]  Mind the installation direction of snap pin and install the snap pin with the hook facing downward.
      G12347714Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the floor console assembly.

    (Refer to Body "FLOOR CONSOLE ")

  5. Install the knob (A) by pressing it in the direction of arrow after installing the boots to the console upper cover.
    G12347715Courtesy of KIA MOTORS AMERICA, INC.
  6. Install the shift cable (B) to bracket and then lightly tighten the nut (A).
    G12347716Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: The existing shift cable clip must be replaced with new one. (Do not reuse it.)
  7. Tighten the nut (A) to the specified torque after removing free play by pushing the shift cable (B) in the direction of the arrow.

    Tightening Torque: 

    9.8 - 14.7 N.m (1.0 - 1.5 kgf.m, 7.2 - 10.8 lb.ft)

    G12347717Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the high voltage cable (A) and HPCU tray (B).

    Tightening Torque: 

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

    G12347718Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the hybrid power control unit (HPCU) assembly.

    (Refer to Hybrid Control System - "HYBRID POWER CONTROL UNIT "

  10. Install the air cleaner assembly and air duct.

    (Refer to Engine Mechanical System - "AIR CLEANER ")

  11. Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the KDS/GDS.

    (Refer to Hybrid Motor System - "COOLANT ")

  12. Connect the high voltage circuit.

    (Refer to Automatic Transaxle System - "HIGH VOLTAGE SHUTOFF PROCEDURE ")

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:

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

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