Kia Optima Hybrid: Automatic Transaxle System / Automatic Transaxle Repair procedures

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 Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.
Shut off the high voltage circuit.
( Refer to Automatic Transaxle System - "High Voltage Shut-off Procedure")
Remove the under cover (A).

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

Drain the coolant of hybrid motor cooling system.
( Refer to Hybrid Motor System - "Coolant")
Drain the coolant of engine & transaxle cooling system.
(Refer to Engine Mechanical System - "Coolant ")
Remove the hybrid power control unit assembly.
( Refer to Hybrid Control System - "HPCU (Hybrid Power Control Unit)"
Remove the duct (A).

Tightening torque:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

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)

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.

Remove the hybrid power control unit (HPCU) tray (A).

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

Remove heater hose pump (A).

Disconnect the solenoid valve connector (B) and inhibitor switch connector (A).

Disconnect the resolver sensor connector (A) and then remove the wiring bracket (B, C).

Remove the motor connector (A).

Remove the electric oil pump (EOP) connector (A).

Remove the shift cable (C) after removing the nut (A) and the bolt (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, 10.8 ~ 15.9 lb-ft)

Remove the ground line after removing the bolt (A).

Remove the ATF warmer hose (A).

Remove the automatic transaxle upper mounting bolt (A-2ea).

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

Assemble the engine support fixture.
(Refer to Special Service Tools-"Engine support fixture special tool assembly drawing")
Using the engine support fixture, hold the engine and transaxle assembly safely.

Remove the cover (A).

Remove the automatic 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)

Remove the automatic transaxle support bracket (A).

Tightening torque:
58.8 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

Remove the electric oil pump (EOP) connector (A) and clips (B).
Remove the clutch pressure sensor (CPS) connector (C).

Remove the Drive shaft assembly.
(Refer to Driveshaft and axle - "Driveshaft Assembly")
Remove the Sub frame assembly.
(Refer to Suspension System - "Front Suspension System")
Remove the heat protector (A).

Tightening torque:
Transaxle side : 11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
Engine side : 21.6 ~ 25.5 N.m (2.2 ~ 2.6 kgf.m, 15.9 ~ 18.8 lb-ft)

Remove the mounting bolts (A, B) after supporting the transaxle by a jack.

Tightening torque:
(A) 42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)
(B) 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Remove the transaxle while slowly lower the jack.
Be careful not to damage other system or parts when removing the transaxle assembly.
Install in the reverse order of removal.
If install the new transaxle, remove the hanger bracket (A) and then install the transaxle.
(Does not need to be re-installed)

If the oil seal on the transaxle is damaged and fluid is leaking, replace the oil seal . When installing the new oil seal, use the specialized tool (oil seal installer: 09452-3D100).
Perform the procedures below after replacing the transaxle.
Refill the automatic transaxle with fluid.
(Refer to Hydraulic System - "Fluid")
Refill the engine & transaxle system with coolant.
(Refer to Engine Mechanical System - "Coolant ")
Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Hybrid Motor System - "Coolant")
Clear the diagnostic trouble codes (DTC) using the GDS. Even though disconnecting the battery negative terminal, the DTCs will not be cleared. So, be sure to clear the DTCs using the GDS.
Reset the automatic transaxle adaptive values using the GDS.

Perform the resolver sensor calibration using the GDS.
(Refer to Hybrid Motor System - "Resolver Sensor")
Perform the clutch pressure sensor calibration using the GDS.
(Refer to Hybrid Control System - "Clutch Pressure Sensor")
Perform the TCM adaptive values learning procedure.
(Refer to Automatic Transaxle Control System - "Repair Procedures")
Automatic Transaxle Components and Components Location

Components 1. Motor assembly2. Electric oil pump (EOP)3. Automatic transaxle case4. Rear cover5. Valve body cover6. Manual control lever7. Air breather hose8. Inhibitor switch9. Solenoid valve connector10. ...

Hydraulic System


Other information:

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