Kia Optima Hybrid: Hydraulic System / Valve Body 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")
2.
Remove the under cover (A).

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

3.
Drain the coolant of hybrid motor cooling system.
(Refer to Hybrid Motor System - "Coolant")
4.
Drain the coolant of engine & transaxle cooling system.
(Refer to Engine Mechanical System - "Coolant")
5.
Remove the drain plug (A) and reinstall the drain plug after draining ATF totally.

Tightening torque :
33.3 ~ 43.1 N.m (3.4 ~ 4.4 kgf.m, 24.6 ~ 31.8 lb-ft)

6.
Remove the wire ring fixed clip (A).

7.
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)

8.
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 ~ 3.6lb-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.

9.
Remove the hybrid power control unit assembly.
( Refer to Hybrid Control System - "HPCU (Hybrid Power Control Unit)")
10.
Remove the HPCU tray (A).

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

11.
Remove the automatic oil cooler tube (A).

Tightening torque:
Eye bolt : 41.2 ~ 47.1 N.m (4.2 ~ 4.8 kgf.m, 30.4 ~ 34.7 lb-ft)
Bracket bolt: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

12.
Remove the ATF Warmer hose (A) and then remove the valve body cover (B).

Tightening torque:
11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)

13.
Remove the oil temperature sensor (A) and solenoid valve connector assembly (B).

14.
Remove the valve body assembly (A).

Tightening torque:
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Installation
1.
Install in the reverse order of removal.
   
Do not reuse the drain plug gasket and the valve body cover gasket, oil cooler tube washer.
Be careful not to damage the hose when tightening the clamp.
Install the clamp in the specified direction to prevent interference with surrounding components.
Perform the procedures below after replacing the valve body.
1)
Refill the automatic transaxle with fluid.
(Refer to Hydraulic System - "Fluid")
2)
Refill the engine & transaxle cooling system with coolant.
(Refer to Engine Mechanical System - "Coolant")
3)
Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS.
(Refer to Hybrid Motor System - "Coolant")
4)
Reset the automatic transaxle adaptive values using the GDS.
5)
Perform the TCM adaptive values learning procedure.
(Refer to Automatic Transaxle Control System - "Repair procedures")
6)
Confirm the coolant leak or fluid leak from the hose connections part in state of engine start.
Valve Body Components and Components Location

Component Location 1. Automatic transaxle2. Valve body assembly Component 1. Pressure Control Valve(PCV) adjust screw8. Underdrive Brake Control Solenoid Valve(UD/B)2. Solenoid valve bracket9. 26 Brake ...

ATF Warmer Description and Operation

Description The ATF warmer is mounted on the valve body cover to reduce oil viscosity friction by increasing oil temperature under cold condition, which in turn improves fuel efficiency. It is serial mounted ...

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