Engine Mechanical System - General Information - Hev: Other Kia Optima III

Mechanical 15 illustrations ~641 words

Safety Precaution

This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution.

WARNING

A caution label for high voltage is attached to the high voltage components. The color of the high voltage cables and connectors are orange. Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE).

Note. High Voltage Component: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor etc.

WARNING

For your safety when servicing the hybrid vehicle: Wear Personal Protection Equipment (Insulation Gloves and Safety Glasses). Do not carry any metallic object (clock, ring etc.) which can cause short circuit. Use insulated tools Before wearing the protective gear, make sure that they are not torn or broken and free of moisture.

Note. Personal Protection Equipment: Insulating Gloves, Safety Glasses

Insulating Gloves Safety Glasses

WARNING

Use Mega Ohm Tester when measuring insulation resistance of the high voltage system.

Specification: High Impedance Digital Volt / Ohm Meter (DVOM) "Category 3" Leads and Meter rated to 1, 000 voltage.

WARNING

Be sure to shut off the high voltage circuit shown in the procedures below before working on any high voltage system component (Refer to " HIGH VOLTAGE SHUTOFF PROCEDURE " for more detailed procedures).

Scheme 514

Turn the ignition switch off and disconnect the auxiliary 12V battery negative (-) cable.
Remove the safety plug (Turning the ignition switch ON with the safety plug removed may damage the hybrid control system).
Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
Remove the rear seat and partition tray trim (Refer to " «FRONT SEAT BELT»(ref-535710-S40556187422013031200000) " in BD group).
Remove the high voltage front cover (A). Measure the voltage between the inverter positive and negative power cable terminals.

Below 30V: High voltage circuit properly shut

More than 30V: High voltage circuit faulty

CAUTION

Attach the 'High Voltage Caution Car Topper' to the vehicle roof to inform other people of danger of high voltage.

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WARNING

Be sure to follow instructions below when repairing the high voltage cable. Check the voltage of the high voltage connector, terminal or busbar before repairing. Below 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty Be careful not to short circuit between positive (+) and negative (-) terminals. Insulate the high voltage connector or terminal with an insulation tape after disconnecting. Tighten the high voltage terminal with the specified torque.

CAUTION

The high voltage battery must be always handled horizontally during repairing or storage. Otherwise, there may be decline in battery performance or its life may be shortened.

CAUTION

Exposing the high voltage battery to intense heat may cause deterioration. Do not bake over 70°C (158°F) / 30 min or 80°C (176°F) / 20 min when painting.

Hybrid Vehicle Refrigerant Recovery / Charging Precautions

Since the electric compressor uses high-voltage, you should use PVE oil which have high Volumetric Resistivity.
Do not use the same A/C recovery / charging station as conventional belt-driven compressors.

WARNING

If the PVE oil of the system gets mixed PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.

High Voltage Shutoff Procedure

WARNING

Shut off the high voltage circuit before doing any work related with the high voltage system (Battery Pack Assembly, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC Power Cable, Electric Compressor, and so on).

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Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.
Remove the safety plug. Open the safety plug service cover (A). Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug.
Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
Make sure that the capacitor has been discharged. Remove the rear seat and partition tray trim (Refer to " «FRONT SEAT BELT»(ref-535710-S40556187422013031200000) " in BD group). Remove the high voltage front cover (A). High voltage front cover installation bolt: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) Measure the voltage between the inverter positive and negative power cable terminals. Below 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty WARNING: If the measured voltage is more than 30V, check the removal of the safety plug again. If it is above 30V even though the safety plug is properly removed, there must be any serious problem in high voltage circuit. In this case, do the DTC troubleshooting first (Refer to DTC Guide); don't do any work related to the high voltage system.

Special Service Tools

Tool (Number and name) Illustration Use Crankshaft front oil seal installer (09214-3K000) (09231-H1100) Installation of the front oil seal 09214-3K000 (installer) 09231-H1100 (handle) Valve stem seal installer (09222-4A000) Installation of the valve stem seal Valve spring compressor (09222-3K000) (09222-3K100) Removal and installation of the intake or exhaust valve 09222-3K000 (compressor) 09222-3K100 (holder) Crankshaft rear oil seal installer (09214-3K100) (09231-H1100) Installation of the crankshaft rear oil seal 09214-3K100 (installer) 09231-H1100 (handle) Torsion damper stopper (09231-3D100) (09231-3D200) Removal and installation of crankshaft pully bolt. 09231-3D100 (Ring gear stopper) 09231-3D200 (Torsion damper stopper adapter) Torque angle adapter (09221-4A000) Installation of bolts & nuts needing an angular method of adjustment. Timing chain tensioner ratchet holder (09240-2G000) Timing chain tension release in vehicle inspection and adjustment of valve clearance. Oil pan remover (09215-3C000) Removal of oil pan Drive belt installer (09252-03200) Installation of the water pump drive belt Drive belt remover (09252-3D100) Removal of the water pump drive belt