2017 Kia Optima Plug-In Hybrid EXFACTORY OEM SERVICE PROCEDURE

Repair Procedures: Removal

WARNING:
  • Be sure to read and follow the "GENERAL SAFETY INFORMATION AND CAUTION " before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
  • Be sure to shut off the high voltage circuit according to the "HIGH VOLTAGE SHUTOFF PROCEDURE " before doing any work related with the high voltage system to avoid serious electrical injuries.
  1. Shut off the high voltage circuit.

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

  2. Remove the under cover.

    (Refer to Engine Mechanical System - "ENGINE ROOM UNDER COVER ")

  3. Drain the coolant of engine & transaxle cooling system.

    (Refer to Engine Mechanical System - "COOLANT ")

  4. Drain the coolant of hybrid motor cooling system.

    (Refer to Hybrid Motor System - "COOLANT ")

  5. Remove the air cleaner assembly and air duct.

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

  6. Remove the hybrid power control unit (HPCU) assembly.

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

  7. Remove 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)

    G12347721Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the solenoid valve connector (A) and inhibitor switch connector (B) and then remove the wiring from the bracket (C).
    G12347722Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the shift cable (C) after loosening the nut (A) and bolts (B).

    Tightening torque: 

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

    (B) 14.7 - 21.6 N.m (1.5 - 2.2 kgf.m, 10.9 - 15.9 lb.ft)

    G12347723Courtesy of KIA MOTORS AMERICA, INC.
  10. Loosen the ground bolt (A).
    G12347724Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the hybrid drive motor high voltage connector (A).
    G12347725Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the electric oil pump (EOP) connector (A).
    G12347726Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the engine clutch pressure sensor connector (A).
    G12347727Courtesy of KIA MOTORS AMERICA, INC.
  14. Loosen the heat protector mounting bolt (A).
    G12347728Courtesy of KIA MOTORS AMERICA, INC.
  15. Separate the ATF warmer hose (A).
    G12347729Courtesy of KIA MOTORS AMERICA, INC.
  16. Loosen the transaxle upper mounting bolts (A).

    Tightening torque: 

    42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb.ft)

    G12347730Courtesy of KIA MOTORS AMERICA, INC.
  17. Assemble the engine support fixture on the engine room.

    (Refer to Special Service Tools - "ENGINE SUPPORT FIXTURE ASSEMBLY DRAWING ")

    G12347731Courtesy of KIA MOTORS AMERICA, INC.
  18. Support the transaxle on a jack.
    G12347732Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the cover (A).
    G12347733Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the transaxle mounting bracket bolts (A).

    Tightening Torque: 

    107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb.ft)

    G12347734Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the transaxle support bracket (A).

    Tightening Torque: 

    58.9 - 78.5 N.m (6.0 - 8.0 kgf.m, 43.4 - 57.9 lb.ft)

    G12347735Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the sub frame.

    (Refer to Suspension System - "SUB FRAME ")

  23. Remove the drive shaft assembly.

    (Refer to Driveshaft and Axle - "FRONT DRIVESHAFT ")

  24. Remove the wiring fixing clip (A) from the valve body.
    G12347736Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the resolver & temperature sensor connector (A).
    G12347737Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the electric oil pump (EOP) connector (A) and mounting clip (B).
    G12347738Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: How to disconnect the connector
    1. Pull the it while pushing hook (B) after releasing the lock pulling the lever (A).
      G12347739Courtesy of KIA MOTORS AMERICA, INC.
    2. Pull the connector while raise the hook (C) using driver.
    G12347740Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the roll rod support bracket (A).

    Tightening Torque: 

    49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb.ft

    G12347741Courtesy of KIA MOTORS AMERICA, INC.
  28. Loosen the transaxle lower mounting bolts (A, B) after supporting the transaxle safely on a jack.

    Tightening Torque: 

    (A) 42.2 - 54.0 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb.ft)

    (B) 42.2 - 48.1 N.m (4.3 - 4.9 kgf.m, 31.1 - 35.4 lb.ft)

    G12347742Courtesy of KIA MOTORS AMERICA, INC.
  29. After separating the transaxle from the engine, remove the transaxle by lowering the jack slowly.
    NOTE: Be careful not to damage other nearby systems or parts when removing the transaxle assembly.
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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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