2011-2012 Kia Optima Service & Repair Manual
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OPTIMA(TF HEV) > 2011 > G 2.4 HEV > General Information
General Information > General Information > General Safety Information and Caution
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.
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).
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.
• 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.
Personal Protection Equipment : Insulating Gloves, Safety Glasses
Insulating Gloves Safety Glasses
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Use Mega Ohm Tester when measuring insulation resistance of the high voltage system.
Specification : High Impendance Digital Volt / Ohm Meter (DVOM) "Category 3"
Leads and Meter rated to 1,000 voltage.
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).
1. Turn the ignition switch off and disconnect the auxiliary 12V battery negative (-) cable.
2. Remove the safety plug (Turning the ignition switch ON with the safety plug removed may damage the
hybrid control system).
3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
4. Remove the rear seat and partition tray trim (Refer to “Seat” in BD group).
5. 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
Attach the 'High Voltage Caution Car Topper' to the vehicle roof to inform other people of danger of high
voltage.
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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.
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.
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.
General Information > General Information > 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.
2. Remove the safety plug.
(1) Open the safety plug service cover (A).
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KIA Optima 2011-2012 Factory Service Repair Manual
Introducing the KIA Optima 2011-2012 Factory Service Repair Manual! This comprehensive manual is specifically designed to assist you in maintaining and repairing your KIA Optima from the years 2011 to 2012.
- Provides detailed instructions: This manual contains step-by-step instructions, illustrations, diagrams, and specifications, ensuring that you have all the information you need to effectively service your vehicle.
- Covers all aspects: Whether it's routine maintenance or major repairs, this manual covers all aspects of your KIA Optima's engine, electrical systems, brakes, suspension, transmission, and more.
- Quality factory manual: Rest assured, this manual is an official factory publication, meaning it is specifically designed by KIA to meet the highest standards of quality and accuracy.
- Saves time and money: By using this manual, you can save valuable time by following the correct procedures and avoiding unnecessary guesswork. Additionally, performing your own repairs can save you money on costly dealership visits.
- Compatible models:
- KIA Optima 2011
- KIA Optima 2012
Invest in the KIA Optima 2011-2012 Factory Service Repair Manual today and take control of your vehicle's maintenance and repairs. Enjoy the peace of mind that comes with having the knowledge and resources to keep your KIA Optima running smoothly for years to come.
