Kia Optima Hybrid: Automatic Transaxle Control System / Inhibitor Switch Repair procedures

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

Inspection

•	Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.

Power Circuit Inspection

1.	Disconnect the Inhibitor switch connector (A).

2.	Ignition KEY "ON" & Engine "OFF".

Measure voltage between supplied power and ground at inhibitor circuit.

Specification Approx. 12V

Signal Circuit Inspection

1.	Connect the Inhibitor switch connector (A).

2.	Ignition KEY "ON" & Engine "OFF".

Measure voltages between each terminal and chassis ground during shift lever changed "P, R, N, D".

Specification : See below "Signal Code Table"

Signal Code Table

PIN No.	P	P-R	R	R-N	N	N-D	D
Signal "1"	12V	12V	0	0	0	0	0
Signal "2"	0	12V	12V	12V	0	0	0
Signal "3"	0	0	0	12V	12V	12V	0
Signal "4"	0	0	0	0	0	12V	12V

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.	Place the shift lever into the "N" position.

3.	Remove the under cover (A).

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

5.	Remove the air duct (A).

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).

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

8.	Remove the tray (A).

9.	Remove the inhibitor switch (A).

10.	Remove the shift cable mounting nut (B).

11.	Remove the manual control lever (B) and the washer after removing a nut (A).

12.	Remove the inhibitor switch (A) after removing the bolts (2ea).

Installation

1.	Check that the shift lever is placed in the "N" position

Install the inhibitor switch (A).

Lightly tighten the inhibitor switch mounting bolts so that necessary adjustments can be made.

Install the manual control lever (A).

Lightly tighten the manual control lever nut (B) so that necessary adjustments can be made.

4.	Align the hole (A) in the manual control lever with the "N" position hole (B) of the inhibitor switch and then insert the SST inhibitor switch guide pin (09480-A3800).

Tighten the nut (A) and bolts (B) with the specified torque.

Tightening torque:

A : 17.7 ~ 24.5 N.m (1.8 ~ 2.5 kgf.m, 13.0 ~ 18.1 lb-ft)

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

6.	Remove the SST (09480-A3800).

7.	Connect the inhibitor switch connector (A).

Install the shift cable by tightening nut (B).

Lightly tighten the shift cable mounting nut (B) so that necessary adjustments can be made.

Push the shift cable to the arrow "F" to eliminate free play and then tighten the nut (A) with the specified torque.

Tightening torque :

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

10.

Install the tray (A).

Tightening torque :

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

11.	Install the hybrid power control unit assembly. ( Refer to Hybrid Control System - "HPCU (Hybrid Power Control Unit)")

12.

Install 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.

13.

Install the air duct (A).

Tightening torque :

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

14.

Install the under cover (A).

Tightening torque:

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

15.	Connect the high voltage circuit.

16.	Refill the hybrid motor cooling system with coolant and then perform the air bleeding using the GDS. (Refer to Hybrid Motor System - "Coolant")

Inhibitor Switch Schematic Diagrams

Circuit Diagram ...

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