KIA OPTIMA PLUG-IN HYBRID 2017 Service Manual

WARNING
As with all batteries, avoid fluid con‐tact with the Hybrid battery. If thebattery is damaged and if electro‐lyte comes in contact with yourbody, clothes or eyes, immediatelyflush with a large quantity of freshwater.
WARNING
Do not use an after-market batterycharger to charge the Hybrid bat‐tery. Doing so may result in death orserious injury.
WARNING
nHigh Waters
•Avoid high waters as this may re‐sult in your vehicle becoming satu‐rated with water and could com‐promise the high voltage compo‐nents.
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(Continued)
•Do not touch any of the high volt‐age components within your vehi‐cle if your vehicle has been sub‐merged in water equal to half ofthe vehicle height. Touching highvoltage components once sub‐merged in water could result in se‐vere burns or electric shock thatcould result in death or serious in‐jury.
WARNING
nCarrying Liquids in Trunk
Do not load large amounts of waterin open containers into the vehicle. Ifthe water spills onto the HEV bat‐tery, it may cause a short and dam‐age the battery.
CAUTION
nCleaning Engine
When you clean the engine compart‐ment, do not wash using water. Wa‐ter may cause electric arcing to oc‐
(Continued)
(Continued)
cur and damage electronic parts andcomponents.
WARNING
nExposure to High Voltage
•High voltage in the hybrid batterysystem is very dangerous and cancause severe burns and electricshock. This may result in seriousinjury or death.
•For your safety, never touch, re‐place, dismantle or remove anyportion of the hybrid battery sys‐tem including components, cablesand connectors.
WARNING
nUse of Water or Liquids
If water or liquids come into contactwith the hybrid system components,and you are also in contact with thewater, severe injury or death due toelectrocution may occur.
Hybrid system overview
1-32

WARNING
nHot Components
When the hybrid battery system op‐erates, the HEV battery system canbe hot. Heat burns may result fromtouching even insulated componentsof the HEV system.
Safety plug
DANGER
Never touch the safety plug. Safetyplug is attached to high voltage hy‐brid battery system. Touching safe‐ty plug will result in death or seriousinjury. Service personnel should fol‐low procedure in service manual.
Some special features of the
hybrid vehicle
Hybrid vehicles sound different than
gasoline engine vehicles. When the hy‐ brid system operates, you may hear a
sound from the hybrid battery system
behind the rear seat. If you apply the accelerator pedal rapidly, you may hear
a sound. When you apply the brake
pedal, you may hear a sound from the regenerative brake system. When the
hybrid system is turned off or on, you
may hear a sound in the engine com‐ partment. If you depress the brake
pedal repeatedly when the hybrid sys‐
tem is turned on, you may hear a sound in the engine compartment.
None of these sounds indicate a prob‐
lem.
They are characteristics of hybrid vehi‐ cles. When the hybrid system is turned on,
the engine may run. This does not indi‐
cate a malfunction. If the "READY" symbol is on, the hybrid system is op‐
erating. Even if the gasoline engine is
off, you can operate the vehicle.
The HEV system may emit electromag‐ netic waves which can affect the per‐
formance of electronic devices applian‐
ces, such as laptop computers, which are not part of the vehicle design.
If you park the vehicle for a long time,
the hybrid system will discharge. You
need to drive the vehicle several times per month to maintain a charge.
When you start the hybrid system in
the "P" transmission position, the
"READY" symbol is illuminated in the cluster. The driver can drive the vehicle
even if the engine is stopped.
WARNING
When you leave the vehicle, youshould turn off the hybrid system. Ifyou depress the accelerator pedal bymistake and the vehicle is not in the"P" position, the vehicle will acceler‐ate. This may result in serious injuryor death.

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1
Hybrid system overview

Virtual Engine Sound System
(VESS)
The Virtual Engine Sound System gen‐
erates an engine sound for pedestrians to hear vehicle while at low speeds in
EV mode.
High voltage battery air intake
Hybrid battery air intake
The hybrid battery air intake is located
on the bottom of the rear seats. The air intake cools down the hybrid bat‐
tery. When the hybrid battery air in‐
take is blocked, the hybrid battery may be overheated. Do not obstruct the air
intake with any other objects.
Plug-in Hybrid Vehicle
0+')1-
The high-voltage battery air intake is
located on the left side of the rear seats. The air intake cools down the
high-voltage battery.
When the high-voltage battery air in‐
take is blocked, the high-voltage bat‐ tery may be overheated and the vehicle
performance may become limited and
set a hybrid warning lamp. Do not ob‐ struct the air intake with any other ob‐
jects.
WARNING
nAir Intake
•Blocking the air intake behind therear seats may damage the HEVbattery.
•Do not allow any water into the airintake even when cleaning. If anywater enters the air intake, theHybrid battery may cause an elec‐tric shock which can cause seriousinjury or death due to electrocu‐tion.
If an accident occurs
• Avoid the engine compartment.
• Avoid any orange or high voltage wires, cables, or components.
• Assume that a high voltage compo‐ nent is exposed and move away fromthe vehicle as promptly as possible.
• Refer to L

WARNING
•After parking the vehicle, shift thetransmission into "P" position. Turnoff the hybrid system by pushingthe Engine Start/Stop button.
•For your safety, do not touch highvoltage cables, connectors andpackage modules. High Voltagecomponents are orange in color.
•Exposed cables or wires may bevisible inside or outside of the ve‐hicle. Never touch the wires or ca‐bles, because an electrical shockmay occur causing injury or death.
•If a fire occurs, to extinguish asmall high-voltage battery fire,the following techniques can beused:-Dry chemical
-CO2
-Large amounts of water
-Regular foamFor a large high-voltage batteryfire, use these types of extin‐guishing methods:
-Large amounts of water
-Fog
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-Regular foam
•If you need towing, refer to L

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3.Leave the vehicle and evacuateto the safety place.
4.Call emergency services for helpand let them know the vehicle isa Hybrid vehicle.
If you have an extinguisher, extin‐guish a fire carefully.Do not touch high voltage cables,connectors and package modules.High voltage components are orangein color.Exposed cables or wires may be visi‐ble inside or outside of the vehicle.Never touch the wires or cables, be‐cause an electrical shock may occurcausing injury or death.
WARNING
If a submersion in water occurs:If your vehicle was flooded and hassoaked carpeting or water on theflooring, you should not try to startthe Hybrid system. Never touch thehigh voltage cables, connectors andpackage modules, because an elec‐
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trical shock may occur causing injuryor death. High Voltage cables are or‐ange in color.We recommend that the car towedto an authorized Kia dealer.
When the hybrid vehicle shuts
off
When the high voltage battery or 12-
volt battery discharges, or fuel tank is empty, the hybrid system may not op‐
erate.
If the Hybrid system stops operating
while the vehicle is moving, reduce the vehicle speed gradually. Pull your vehi‐
cle off the road in a safe area, and shift
the transmission in to Park (P) position and: 1. Turn on the hazard warning flash‐ ers.
2. Set the start button at OFF, and try to start the Hybrid system by ap‐
plying the brake pedal and pushing
the start button.
3. If the Hybrid system will not oper‐ ate, refer to L

How to use this manual........................................................... 2-02
Fuel requirements..................................................................... 2-03Gasoline engine..................................................................... 2-03
Vehicle break-in process.......................................................... 2-06
HEV powertrain......................................................................... 2-07
Introduction

2

HOW TO USE THIS MANUAL
We want to help you get the greatest possible driving pleasure from your ve‐
hicle. Your Owner’s Manual can assist
you in many ways. We strongly recom‐ mend that you read the entire manual.
In order to minimize the chance of
death or injury, you must read the WARNING and CAUTION sections in the
manual.
Illustrations complement the words in
this manual to best explain how to en‐ joy your vehicle. By reading your man‐
ual, you learn about features, impor‐
tant safety information, and driving tips under various road conditions.
The general layout of the manual is
provided in the Table of Contents. Use
the index when looking for a specific area or subject; it has an alphabetical
listing of all information in your manual.
Sections: This manual has ten chapters
plus an index. Each section begins with a brief list of contents so you can tell at
a glance if that section has the infor‐
mation you want. You will find various WARNINGs, CAU‐
TIONs, and NOTICEs in this manual.
These WARNINGs were prepared to en‐
hance your personal safety. You should carefully read and follow ALL proce‐
dures and recommendations provided
in these WARNINGs, CAUTIONs and NO‐ TICEs.
WARNING
A WARNING indicates a situation inwhich harm, serious bodily injury ordeath could result if the warning isignored.
CAUTION
A CAUTION indicates a situation inwhich damage to your vehicle couldresult if the caution is ignored.
NOTICE
A NOTICE indicates interesting or
helpful information is being provi‐
ded.
Introduction
2-02

FUEL REQUIREMENTS
Gasoline engine
Unleaded
For Europe
For the optimal vehicle performance,
we recommend you to use unleaded gasoline with an octane rating of RON
(Research Octane Number) 95 / AKI
(Antiknock Index) 91 or higher.
You may use unleaded gasoline with an octane rating of RON 91~94 / AKI 87~90
but it may result in slight performance
reduction of the vehicle. (Do not use methanol blended fuels.)
Except Europe
Your new Kia vehicle is designed to use
only unleaded fuel having an Octane
Rating of RON (Research Octane Num‐ ber) 91 / AKI (Antiknock Index) 87 or
higher. (Do not use methanol blended
fuels.)
Your new vehicle is designed to obtain maximum performance with UNLEA‐
DED FUEL, as well as minimize exhaust
emissions and spark plug fouling.
CAUTION
NEVER USE LEADED FUEL. The useof leaded fuel is detrimental to thecatalytic converter and will damagethe engine control system’s oxygensensor and affect emission control.Never add any fuel system cleaningagents to the fuel tank other thanwhat has been specified. (We recom‐mend that you consult an authorizedKia dealer for details.)
WARNING
•Do not "top off" after the nozzleautomatically shuts off when re‐fueling.
•Always check that the fuel cap isinstalled securely to prevent fuelspillage in the event of an acci‐dent.
Leaded (if equipped)
For some countries, your vehicle is de‐
signed to use leaded gasoline. When you are going to use leaded gasoline,
we recommend that you ask an au‐
thorized Kia dealer whether leaded gasoline in your vehicle is available or
not.
Octane Rating of leaded gasoline is
same with unleaded one.
Gasoline containing alcohol and
methanol
Gasohol, a mixture of gasoline and
ethanol (also known as grain alcohol), and gasoline or gasohol containing
methanol (also known as wood alcohol)
are being marketed along with or in‐ stead of leaded or unleaded gasoline.
Do not use gasohol containing more
than 10% ethanol, and do not use gas‐
oline or gasohol containing any metha‐ nol. Either of these fuels may cause
drivability problems and damage to the
fuel system, engine control system and emission control system.
Discontinue using gasohol of any kind if
drivability problems occur.
Vehicle damage or drivability problems
may not be covered by the manufac‐ turer’s warranty if they result from the
use of:

2-03
2
Introduction

1. Gasohol containing more than 10%ethanol.
2. Gasoline or gasohol containing methanol.
3. Leaded fuel or leaded gasohol.
CAUTION
Never use gasohol which containsmethanol. Discontinue use of anygasohol product which impairs driva‐bility.
Other fuels
Using fuels such as - Silicone (Si) contained fuel,
- MMT (Manganese, Mn) contained
fuel,
- Ferrocene (Fe) contained fuel, and
- Other metalic additives contained
fuels, may cause vehicle and engine
damage or cause plugging, misfiring,
poor acceleration, engine stalling, catalyst melting, abnormal corrosion,
life cycle reduction, etc.
Also, the Malfunction Indicator Lamp
(MIL) may illuminate.
NOTICE
Damage to the fuel system or per‐
formance problem caused by the
use of these fuels may not be cov‐
ered by your New Vehicle Limited
Warranty.
Use of MTBE
Kia recommends avoiding fuels contain‐
ing MTBE (Methyl Tertiary Butyl Ether) over 15.0% vol. (Oxygen Content 2.7%
weight) in your vehicle.
Fuel containing MTBE over 15.0% vol.
(Oxygen Content 2.7% weight) may re‐ duce vehicle performance and produce
vapor lock or hard starting.
CAUTION
Your New Vehicle Limited Warrantymay not cover damage to the fuelsystem and any performance prob‐lems that are caused by the use offuels containing methanol or fuelscontaining MTBE (Methyl TertiaryButyl Ether) over 15.0% vol. (OxygenContent 2.7% weight.)
Do not use methanol
Fuels containing methanol (wood alco‐ hol) should not be used in your vehicle.
This type of fuel can reduce vehicle
performance and damage components of the fuel system, engine control sys‐
tem and emission control system.
Fuel Additives
Kia recommends that you use unleaded
gasoline which has an octane rating of RON (Research Octane Number) 95 /
AKI (Antiknock Index) 91 or higher (for
Europe) or Octane Rating of RON (Rea‐ search Octane Number) 91 / AKI (Anti‐
knock Index) 87 or higher (except Eu‐
rope).
For customers who do not use good quality gasolines including fuel additives
regularly, and have problems starting
or the engine does not run smoothly, one bottle of additives added to the
fuel tank at every 15,000 km (For Eu‐
rope)/ 10,000 km (Except Europe). Addi‐
tives are available from your authorized
Kia dealer along with information on
how to use them. Do not mix other ad‐
ditives.
Operation in foreign countries
If you are going to drive your vehicle in
another country, be sure to:
Introduction
2-04

• Observe all regulations regarding reg‐istration and insurance.
• Determine that acceptable fuel is available.

2-05
2
Introduction