OE Hybrid Information is Essential Alternative Vehicle Systems
By Jeff Webster, ALLDATA Technical Writer
Even though hybrid vehicles have been around for a few years,
they still present some unique challenges to both the automotive
service and collision repair industries.
Manufacturers are working to develop new alternative fuel systems
while continuing to refine their existing ones.That means that
up-to-date OE procedures are an absolute necessity for proper and
safe repairs. The issue of technician safety alone demands
Here, for example, is an excerpt from a technical service
bulletin (TSB) issued by Kia® for an Optima® Hybrid. Some
information may have been edited and/or reformatted for the
purpose of this article:
Kia High Voltage Shutoff Procedure
2012 Kia Optima L4-2.4L Hybrid
Always refer to ALLDATA Repair® S3000 or ALLDATA Collision®
S3500 for safety procedures, identification of material types,
recommended refinish materials, and removal and installation
procedures. Always refer to the vehicle manufacturer for
questions relating to applicable or non-applicable warranty
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).
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) (Figure
(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 (Figures 2 & 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.
(2) Remove the high voltage front cover (A) (Figure
• 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 (Figure 5).
• Below 30V: High voltage circuit properly
shut. • More than 30V: High voltage circuit
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 a serious problem in high
voltage circuit. In this case, do the DTC troubleshooting first;
do not do any work related to the high voltage system.
NOTE: This Repair/Service Procedure is excerpted
from a Technical Service Bulletin published by the vehicle
manufacturer, and is intended for use by trained, professional
technicians with the knowledge, tools and equipment to do the job
properly and safely. It is recommended that this procedure not be
performed by “do-it-yourselfers.”
Kia and Optima are registered trademark names and model
designations of Toyota Motor Corporation and/or Kia Motors
Corporation of Korea. All trademark names and model designations
are being used solely for reference and application purposes.