Kia Optima Hybrid: Brake System / Special Service Tools

Special Service Tools
Tool Name / Number
Illustration
Description
09581-11000
Piston expander

Used when spreading the front and rear brake piston.
09580-3D100
Air bleeding tool

Used when bleeding the air in the brake system.
0k585-E8100
Air bleeding tool

Used when bleeding the air in the brake system.

Personal Protective Equipment
Name
Illustration
Description
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.

Specifications

Specifications ItemSpecificationFront disc brakeTypeVentilated discDisc O.D.O 300 mm (11.81 in)Disc thickness28 mm (1.10 in)Caliper pistonSingleCylinder I.D.O 60 mm (2.36 in)Rear disc brakeTypeSolid discDisc ...

Troubleshooting

Troubleshooting SymptomSuspect AreaReferenceLower pedal or spongy pedal1. Integrated Brake Actuation Unit (Air in)air·bleed2. AHB system (Fluid leaks)replace3. Piston seals in IBAU (Worn or damaged)replaceBrake ...

Other information:

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Special Service Tools


Special Service Tools Tool Name / NumberIIIustrationDescriptionLower arm ball joint remover0K545-A9100Removal of front lower arm from front axle Personal Protective Equipment NameIllustrationDescriptionInsulation gloveUsed when inspecting or working on the high voltage components[Insulation performance ...

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual: Water pump Troubleshooting


Troubleshooting SymptomsPossible CausesRemedyCoolant leakage • From the bleed hole of the water pump Visually check • Check leaks after about ten-minute warming up. • If coolant still leaks, replace a water pump. • If leakage stops, reuse the water pump (Do not replace the pump with a new one). ...

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