Kia Optima Hybrid: 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.
2.
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.
4.
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

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