Kia Optima Hybrid: Automatic Transaxle Control System / Shift Cable Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Automatic Transaxle System / Automatic Transaxle Control System / Shift Cable Repair procedures

Removal

•	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.

1.	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 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

3.	Drain the coolant of hybrid motor cooling system. ( Refer to Hybrid Motor System - "Coolant")

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)

Remove the air cleaner assembly.

(1)	Disconnect the breather hose (A).

(2)	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.

6.	Remove the hybrid power control unit assembly. (Refer to Hybrid Control System - "Hybrid Power Conrol Unit")

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)

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 Body - "Console")

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.

Installation

Install in the reverse order of removal.

•	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 Hybrid Motor System - "Coolant")

Shift Cable Components and Components Location

Components 1. Shift lever assembly3. Shift cable assembly 2. Shift cable retainer? ...

Driveshaft and axle

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Other information:

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Special Service Tools

Personal Protective Equipment NameIllustrationDescriptionInsulation gloveUsed when inspecting or working on the high voltage components[Insulation performance : 1000V / 300A or above]Insulation shoesUsed when inspecting or working on the high voltage componentsInsulation clothesInsulation helmetSafety ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: High Voltage Shut-off Procedures

High Voltage Shut-off 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. • High voltage components: ...