Production year - D: 2013, E: 2014, F: 2015, G: 2016…
Final Drive Ratio - C: 3.320
Detailed Classification - A: Theta-II 2.4 HEV
Spare
Transmission serial number - 000001~999999
Transaxle Number / Location of Warning and Caution Labels
1. Caution for Fans 2. Radiator Cap Warning
3. 12 V Auxiliary Battery Warning 4. High Voltage Warning 5. High Voltage Battery.
12 V Auxiliary Battery Warning Label DescriptionWarning label/caution (continued) A. Keep lit cigarettes and any other flame or sparks away from the battery. B. Wear eye protection when charging or working near the battery. Always provide ventilation when working in an enclosed area.
When lifting a plastic-case battery, excessive pressure on the battery may cause acid leakage, which may result in personal injury. Use a battery lifter or hold the battery at opposite corners by hand.
Never attempt to replace the battery while the battery cables are connected.
The electrical ignition system operates at high voltage. Never touch these components with the engine running or the ignition switch ON.
C. Keep batteries out of reach of children, as batteries contain highly corrosive SULFURIC ACID. Do not allow battery acid to contact skin, eyes, clothing, or paint. D. If electrolyte gets into the eyes, flush eyes with clean water for at least 15 minutes and seek medical attention immediately. If possible, continue flushing with water using a sponge or cloth until medical attention is received. If electrolyte contacts the skin, thoroughly wash the contact area. If you feel pain or a burning sensation, seek medical attention immediately.
E. Always read the following instructions carefully when working with the battery.
F. Hydrogen, which is a flammable gas, is always present in battery cells and may explode if ignited. G. An improperly disposed of battery may harm the environment and human health. Always check local battery disposal regulations. Handling and Storage of the 12 V Auxiliary Battery
Battery Itself
Batteries should be stored in a cool, dry (27 °C/80°F) place, protected from direct sunlight.
MF batteries are tightly sealed to prevent acid leakage. However, tilting the battery at a 45-degree angle may cause acid to leak through the side vent holes. Therefore, always store batteries in an upright position. Do not place any water or solid (i.e., conductive) objects on top of the battery.
It is extremely dangerous to use tools such as hammers on battery terminals when connecting cables to an installed battery.
Battery in the Vehicle
When storing the vehicle for a long period, be sure to remove the memory fuse in the fuse box to prevent natural discharge.
Also, start the engine to recharge the battery for 1 month if the memory fuse was not removed from the start of vehicle storage. If the memory fuse was removed, start the engine to recharge the battery for 3 months from the time the vehicle was placed in storage.
After reconnecting or recharging a discharged battery, the ESC OFF indicator may illuminate. In this case, turn the steering wheel halfway to the left and right while the ignition switch is in the ON position. Then restart the engine after turning the ignition off. The ESC OFF indicator may go off. If the ESC OFF indicator does not go off, inspect the system using the DTC.
Jack and Support Points
When heavy rear components such as the suspension, fuel tank, spare tire, tailgate, and trunk lid are removed, place additional weight in the luggage compartment before lifting. When significant weight is removed from the rear of the vehicle, the center of gravity may shift and may cause the vehicle to tip over on the lift.
Since each tire/wheel assembly weighs approximately 14 kg (30 lb), placing the front wheels in the luggage compartment can help distribute the weight.
Use the same support points when supporting the vehicle on safety stands.
Position the lift pads under the support points as shown in the illustration.
Raise the lift a few inches (centimeters) and rock the vehicle to make sure it is securely supported.
Raise the lift to full height to check the lifting points for secure support.
Towing If the vehicle must be towed, call a professional towing service. Never tow the vehicle using only a rope or chain. This is very dangerous. Emergency Towing There are three common methods of towing a vehicle:
The operator loads the vehicle onto the truck bed. This is the best method for transporting the vehicle.
The tow truck uses two swivel arms that pass under the drive axle wheels and lift them off the ground. The other two wheels remain on the ground.
The tow truck uses metal cables with hooks on the ends. These hooks engage parts of the frame or suspension, and the cables lift one end of the vehicle off the ground. Vehicle suspension and body may be seriously damaged if towing is attempted this way. If the vehicle cannot be transported on a flatbed, it should be towed with the drive wheels off the ground, as follows:
Manual transaxle
Release the parking brake.
Shift the transmission to the NEUTRAL position.
Automatic Transmission
Release the parking brake.
Start the engine.
Shift from [D] to [N].
Turn the engine off.
Vehicles equipped with full-time 4WD must be transported only on a flatbed.
Improper towing preparation may cause damage to the transmission. Follow the procedure described above exactly. If you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flatbed.
It is best to tow the vehicle no more than 30 km (19 miles), and keep the speed below 50 km/h. (For a standard 4WD vehicle, limit towing to 1.5 km (1 mile) and 15 km/h.)
Attempting to lift or tow the vehicle by the bumpers may cause serious damage. Bumpers are not designed to support the weight of the vehicle.
Meaning of Symbols There are five main symbols used to supplement the illustrations. These symbols indicate the parts to which such materials are applied during service.
Symbol
Meaning
Do not reuse the part. Replace with a new one.
Apply engine oil or transmission oil to the part.
Apply automatic transmission fluid (ATF) to the part.
Apply grease to the part.
Apply sealant to the part.
General Service Information Vehicle Protection Always cover fenders, seats and floor before starting work.
Always insert the hood support rod into the hole near the edge of the hood whenever you inspect the engine compartment, to prevent the hood from falling and causing possible injury. Make sure the hood support rod is released before closing the hood. Always check that the hood is securely latched before driving the vehicle.
Preparation of Tools and Measuring Equipment Make sure all necessary tools and measuring equipment are available before starting work. Special Service Tools Use special service tools when required.Parts Removal Always first identify the cause of the problem, then determine whether removal or disassembly is required before starting work.Disassembly If the disassembly procedure is complex and requires removing many parts, all parts must be disassembled in a way that does not affect their function or appearance.
Inspection of Parts: Every part removed must be carefully inspected for malfunction, deformation, damage, and other problems.
Arrangement of Parts: All disassembled parts must be neatly arranged for efficient reassembly. Be sure to separate and properly identify parts to be replaced from those to be reused.
Cleaning of Parts for Reuse: All parts to be reused must be thoroughly cleaned using an appropriate method.
Oil Seals
Gaskets
O-rings
Lock Washers
Cotter Pins
Plastic NutsDepending on their location.
Apply sealant to gaskets.
Apply oil to the moving parts.
Before assembly, apply specified oil or grease to the designated locations (oil seals, etc.).
Be sure to disconnect the battery cable from the negative (-) battery terminal.
Never pull on the wires when disconnecting connectors.
Locking connectors will click when securely connected.
Handle sensors and relays carefully. Be careful not to drop them onto other parts.
In general, all measurements in this manual are made with a caliper.
When using a measuring tape, make sure it does not stretch, twist, or bend.
Both projected and actual dimensions are used for measurements in this manual.
These are dimensions measured when the measuring points are projected from the vehicle surface and are reference dimensions for body repair.
If the length of the tracking sensor rods is adjustable, measure it by extending one of the two probes until the height values of the two surfaces are the same.
These dimensions indicate the actual linear distance between measuring points and are used as reference dimensions when a gauge is used for measurement.
First adjust both probes to the same length (A=A'') before measuring.
Check the probes and gauge to make sure there is no free play.
Check the terminal for tightness.
Check terminals and wires for corrosion from battery electrolyte, etc.
Check terminals and wires for open circuits.
Check wire insulation and coating for damage, cracks, and wear.
Check the conductive parts of the terminals for contact with other metal parts (vehicle body and other components).
Check the grounded parts to make sure there is full continuity between their mounting bolt(s) and the vehicle body.
Check for correct connections.
Make sure the wiring is secured so it does not contact sharp edges of the vehicle body, etc., or hot parts (exhaust manifold, etc.).
Make sure wiring is secured with sufficient clearance from the fan pulley, fan belt, and other rotating or moving parts.
Make sure the wiring has enough slack so that it can absorb vibration between stationary and moving parts, such as the vehicle body and engine.
Before servicing the electrical system, be sure to turn the ignition off and disconnect the battery ground cable.
When diagnosing the MFI or ELC system, disconnecting the battery cable will erase any stored diagnostic trouble codes from the computer memory. Therefore, record diagnostic data before disconnecting the battery cable if necessary.
Secure the wiring harness with clamps so that there is no slack. However, for any harness that runs near the engine or other vibrating parts of the vehicle, allow some slack within a range that prevents engine vibration from causing the harness to contact any of the surrounding parts, then secure the harness with a tie or clamp.
If any section of the wiring harness interferes with the edge of a part or a corner, wrap the section of the harness with tape or similar material to protect it from damage.
When installing any parts, take care not to pinch or damage the wiring harness.
Never drop relays, sensors, or electrical parts, or subject them to strong impact.
Electronic parts used in the computer, relays, etc. are easily damaged by heat. If there is a need for service operations that may cause the temperature to exceed 80 °C, remove the electronic parts before proceeding.
Loose connectors cause problems. Make sure that connectors are always securely fastened.
When disconnecting a connector, hold only the connector, not the wires.
Disconnect the connector with locks by pressing in the direction indicated by the arrows in the illustration.
To connect locking connectors, insert the connectors until they click.
When using a circuit tester to check continuity or voltage at a connector, insert the test probe from the wiring harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until it contacts the terminal, taking care not to damage the wire insulation.
To avoid overloading the wiring, take into account the current load of the additional equipment and determine the appropriate wire size.
Nominal size
SAE Gauge No.
Allowable Current
In Engine Compartment
Other Areas
0.3 mm²
AWG 22
-
5A
0.5 mm²
AWG 20
7A
13A
0.85 mm²
AWG 18
9A
17A
1.25 mm²
AWG 16
12A
22A
2.0 mm²
AWG 14
16A
30A
3.0 mm²
AWG 12
21A
40A
5.0 mm²
AWG 10
31A
54A
Parts: When replacing parts, use genuine KIA MOTORS parts. Replacement: Standard values, such as torques and specified adjustments, must be strictly observed when reassembling all parts. After removal, the following parts should always be replaced with new ones. Adjustment: Use gauges and testers to correctly adjust parts to standard values. Electrical System: Rubber parts and hoses: Always avoid contact of gasoline with rubber parts or hoses. Body Dimensions Measurement: Dimensions: Measuring actual dimensions. Measuring point: Measurements should be taken at the center of the hole. Checking Cables and Wires: Check fuses: Test points are provided on blade-type fuses to check the fuse itself without removing it from the fuse block. The fuse is good if the test lamp lights when connected to the test points of one terminal (one at a time) and the other lead is grounded. (Turn the ignition key so that the fuse circuit is energized.) Electrical System Service: Precautions for catalytic converter
If a large amount of unburned gasoline enters the catalytic converter, it may overheat and create a risk of fire. To prevent this, observe the following precautions and explain them to your customer.
Use only unleaded gasoline.
Do not run the engine when the vehicle has been stationary for a long time. Avoid running the engine at high idle speed for more than 10 minutes or at idle for more than 20 minutes.
Do not measure engine compression for a long period of time. Engine compression test must be performed as quickly as possible. Remove the fuel pump relay before performing the compression test.
Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.
?
Test yourself
A quick Kia Optima Hybrid Owner's Manual quiz: every answer comes with an explanation and a link to the manual page.
