General Information - Optima Hev: Other Kia Optima III рестайлинг

Safety Precaution

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Personal Protective Equipment

Insulation glove Used when inspecting or working on the high voltage components [Insulation performance : 1000V / 300A or above] Insulation shoes Used when inspecting or working on the high voltage components Insulation clothes Insulation helmet Safety glasses Used in the case below During Removal & installation or inspection of the high voltage battery terminals or wiring, which spark might happen. During working on the high voltage battery pack assembly. Face shield Insulation mat Putting the removed high voltage components on the insulation mat to prevent safety accidents. Insulation sheet Covering the high voltage components with insulation sheet to prevent people who don't wear the personal protective equipment from safety accidents

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Hybrid Vehicle Refrigerant Recovery/Charging Precautions

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

High Voltage Shutoff Procedure

Information

1. High voltage components: 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.

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1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.
2. Remove the safety plug. Remove the safety plug cover (A). Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (B) to the direction of arrow.
3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
4. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely Remove air cleaner assembly and air duct. (Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-675056-S40856905402014120400000) ) Disconnect the inverter power cable (A). Information Disconnect the inverter power cable as shown in the procedures below. Measure the voltage between the inverter (+) terminal and the inverter (-) terminal. Less than 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty WARNING: If measured more than 30V, check if the safety plug is removed completely. If measured more than 30V despite the safety plug is removed, it can be serious problems on the high voltage circuit. In this case, check DTC and never touch on the high voltage system.

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1. World Manufacturer Identifier (WMI) KNA: Passenger vehicle, MPV (Multipurpose Passenger Vehicle)/SUV (Sports Utility Vehicle)/RV (Recreational Vehicle)
2. Vehicle line G: OPTIMA
3. Model & Series L: Low grade (L) M: Middle-Low grade (GL) N: Middle grade (GLS, JSL, TAX) P: Middle-High grade (HGS) R: High grade (TOP)
4. Body/Cabin type, Gross Vehicle Weight Rating 4: Sedan - 4 door
5. Restraint system, Brake system Code Seat belt Front air bag Knee air bag Side air bag Curtain air bag Driver's Passenger's Driver's Passenger's 1st row 2nd row 3rd row 1st row 2nd row 3rd row A o o o x x o x x o o x B o o o x x x x x x x x C o o o x x o x x o o o D o o o x x o o x o o x E o o x x x x x x x x x F o o o x x o x x x x x L o o o o x o x x o o x N o x x x x x x x x x x J o o o o x o o x o o o
6. Engine type D: Gasoline engine 2.4 (Theta-II) + HEV
7. Check digit or Driver's side & Transmission Check digit: 0 ~ 9, x
8. Production year A: 2010, B: 2011, C: 2012, D: 2013, E: 2014...
9. Plant of production 5: Hwasung (Korea)
10. Vehicle production sequence number 000001 ~ 999999

PAINT CODE

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1. Engine fuel G: Gasoline
2. Engine range 4: 4 cycle 4 cylinder
3. Engine development order and capacity K: Theta engine (Gasoline)
4. Engine Capacity K: 2359cc (Theta-II HEV engine)
5. Production year A: 2010, B: 2011, C: 2012, D: 2013, E: 2014...
6. Plant of production A: Asan (Korea) B: Beijing (China) H: Hwasung (Korea) K: Montgomery (U.S.A) M: Chennai (India) P: Poseung (Korea) S: Sohari (Korea) T: Izmit (Turkey) U: Ulsan (Korea) W: Shandong (China) Z: Zilina (Slovakia) 1: Yancheng (China)
7. Engine production sequence number 000001 ~ 999999

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1. Model HA: A6MF2H (Theta-II 2.4 HEV)
2. Production year A: 2010, B: 2011, C: 2012, D: 2013, E: 2014...
3. Final gear ratio S: 3.320
4. Detailed classification A: Theta-II 2.4 HEV
5. Spare
6. Transaxle production sequence number 000001~999999

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1. Keep lighted cigarettes and all other flames or sparks away from the battery.
2. Wear eye protection when charging or working near a battery. Always provide ventilation when working in an enclosed space. When lifting a plastic-cased battery, excessive pressure on acid to leak resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Never attempt to change the battery when the battery cables are connected. The electrical ignition system works with high voltage. Never touch these components with the engine running or the ignition switched on.
3. Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow battery acid to contact your skin, eyes, clothing or paint finish.
4. If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received. If electrolyte gets on your skin, thoroughly wash the contacted area. If you feel a pain or a burning sensation, get medical attention immediately.
5. Always read the following instructions carefully when handing a battery.
6. Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.
7. An improperly disposed battery can be harmful to the environment and human health. Always confirm local regulations for battery disposal.

HANDLING AND STORAGE AUXILIARY 12V BATTERY

Note. After reconnecting or recharging a discharged battery, the ESC OFF indicator may illuminate. In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position. Then, restart the engine after the ignition is OFF. The ESC OFF indicator may turn OFF. If the ESC OFF indicator does not turn OFF, have the system checked referring to DTC.

Lift And Support Points

Note. Since each tire/wheel assembly weights approximately 14kg (30lbs), placing the front wheels in the luggage area can assist with the weight distribution. Use the same support points to support the vehicle on safety stands.

1. Place the lift blocks under the support points as shown in the illustration.
2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.
3. Raise the hoist to full height to inspect the lift points for secure support.

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Towing

If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is very dangerous.

Emergency Towing

There are three popular methods of towing a vehicle

1. The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.
2. The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. The other two wheels remain on the ground.
3. The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension, and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously damaged if this method of towing is attempted. If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the driving axle off the ground and do the following

Manual Transaxle

1. Release the parking brake.
2. Shift the Transaxle to neutral

Automatic Transaxle

1. Release the parking brake.
2. Start the engine.
3. Shift to [D] position, then [N] position.
4. Turn off the engine.

Meaning Of Symbols

There are five primary symbols used to complement illustrations. These symbols indicate the part to apply such materials during service.

Symbol Meaning Do not reuse the part. Replace with a new one. Apply engine oil or transmission oil to the part. Apply automatic transmission fluid (ATF) to the part. Apply grease to the part. Apply sealant to the part

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Protection Of The Vehicle

Always be sure to cover fenders, seats, and floor areas before starting work.

Preparation Of Tools And Measuring Equipment

Be sure that all necessary tools and measuring equipment are available starting work.

Parts

When replacing parts, use KIA MOTORS genuine parts.

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Electrical System

1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.
2. Never pull on the wires when disconnecting connectors.
3. Locking connectors will click when the connector is secure.
4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

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Rubber Parts And Tubes

Always prevent gasoline or from touching rubber parts or tubing.

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Measuring Body Dimensions

1. Basically, all measurements in this service information are taken with a tracking gauge.
2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this service information.

Dimensions Projected

1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are the reference dimensions used for used for body alterations.
2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the different value in height of the two surfaces.

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1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference dimensions when a tracking gauge is used for measurement.
2. First adjust both probes to the same length (A=A') before measurement. NOTE: Check the probes and gauge itself to make sure there is no free play.

Measurement Point

Measurements should be taken at the center of the hole.

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Checking Cables And Wires

1. Check the terminal for tightness.
2. Check terminals and wires for corrosion from battery electrolyte, etc.
3. Check terminals and wires for open circuits.
4. Check wire insulation and coating for damage, cracks and degrading.
5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's body.
7. Check for incorrect wiring.
8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, etc.)
9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating or moving parts.
10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle body and the engine.

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Check Fuses

A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is grounded. (Turn the ignition switch so that the fuse circuit becomes operative)

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1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. NOTE: In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code retained by the computer will be cleared. There fore, if necessary, record the diagnostic data before removing the battery cable.
2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness by using a clamp.
3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness with tape or something similar in order to protect if from damage.
4. When installing any parts, be careful not to pinch or damage any of the wiring harness.
5. Never throw relays, sensors or electrical parts, or expose them to strong shock.
6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.
7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.
8. When disconnecting a connector, be sure to grip only the connector, not the wires.
9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.
10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.
11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until contacts the terminal, being careful not to damage the insulation of the wires.
12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriate wire size.

Precautions For Catalytic Converter

1. Use only unleaded gasoline.
2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than 10 minutes and idle speed for more than 20 minutes.
3. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly as possible. Remove the fuel pump relay before performing a compression test.
4. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.