Kia Optima Hybrid: Body (Interior and Exterior) / Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Body (Interior and Exterior) / Repair procedures

High Voltage Shutoff Procedure

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).

1.	Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.

Remove the safety plug.

(1)	Open the safety plug service cover (A).

(2)	Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug.

3.	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.

(1)	Remove the rear seat and partition tray trim (Refer to “Seat” in BD group).

(2)

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)

(3)

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

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.

General Safety Information and Caution

Safety Precaution Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to a serious accidents like electric ...

Specifications

Specifications ItemsSpecificationHoodTypeRear hinged, gas lifter typeFront DoorConstructionFront hinged, frame door constructionRegulator systemWire drum typeLocking systemPin-fork systemRear DoorConstructionFront ...

Other information:

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: ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Interior Body Repair

Interior A Front pillar trim mounting hole (O12)Front pillar trim mounting hole (O8.4)Cowl crossbar mounting hole (O9)Cowl side trim mounting hole(8.4X8.4)Front door checker mounting hole (O13)Seat belt height adjust upper mounting hole (O12)Seat belt height adjust upper mounting hole (O12)Front seat ...