Charging System - High Temperature Battery Drain

VOLUME
3

GROUP
Engine

NUMBER
011

MODEL
Optima

DATE
May 2003

SUBJECT
Optima Charging System - 4 Cylinder Engine

This bulletin provides information related to charging system changes in 2003MY Optima models with 4 cylinder engine to improve alternator output in high ambient temperature severe operating conditions.

Some 2001-2003MY Optima 4 cylinder models built before 5/1/03 may experience battery discharge when operated in high ambient temperatures for extended periods of time at low speeds or at idle with A/C, headlamps and other accessories on. Typically this results in customers reporting an inability to restart vehicle. To reduce incidence of battery discharge complaints, the following changes were made:

^ Battery heat cover added - 12/20/02 production

^ ECM battery compensation revised - 3/25/03 production

^ New 110A alternator installed - 5/1/03 production





For 2001-2003 Optima 4 cylinder complaint vehicles produced before 5/1/03, the revised parts and ECM logic software has been made available for use as a field fix.

BATTERY TEST:





Test battery using Micro 570 Tester, refer to TSB, SST 002 for instructions.

ALTERNATOR INSTALLATION

PROCEDURE:





1. Disconnect battery negative cable.

2. Disconnect alternator electrical connections.

3. Loosen upper alternator bolt and belt tension adjustment.

4. Remove bolt from power steering line bracket.





5. Remove three bolts securing cruise control unit (if equipped).

6. Disconnect cruise control unit electrical connector, and leaving accelerator cable attached, position cruise control unit out of the way for alternator removal.

7. Remove mounting bolts from alternator and remove alternator from vehicle.

8. Install new alternator, adjust belt tension and reconnect electrical connections.

9. Reinstall cruise control unit and reconnect electrical connector.

10. Reinstall power steering line bracket bolt.

11. ^ If vehicle has OEM battery, continue on to Battery Cover Installation procedure.
^ If vehicle has a replacement battery, reconnect negative battery cable and continue on to ECM Reprogram procedure.

BATTERY COVER INSTALLATION:

* NOTICE
Battery cover will only fit OEM battery.

1. Remove both battery cables.





2. Loosen battery hold-down bolt if necessary, and remove old battery cover.





3. Install new battery cover over battery.

4. Reconnect battery cables, positive cable first.

01-02MY ECM REPROGRAMMING

PROCEDURE:





1. Remove program card from the upper slot on Hi-Scan Pro and insert the reprogramming card.





2. Connect reprogramming adapter to Hi-Scan Pro.

3. Connect 10 pin ECU adapter to reprogramming adapter cable.

4. Connect vehicle power adapter to Hi-Scan Pro.

5. Connect reprogramming adapter power cable to vehicle power adapter.





6. Connect Hi-Scan Pro to 10 pin DLC located under the dash near OBDII connector.

7. Connect vehicle power adapter to vehicle power outlet.





8. Turn ignition key to the "ON" position.

9. Turn Hi-Scan Pro on and select "11. OPTIMA 2.4 01/02MY BATTERY DRAIN" and press the "ENTER" key.





10. Select "01 OPTIMA 2.4D BATTERY DRAIN [AUTO]" and press the "ENTER" key.





11. At the prompt, enter your password "0525" and press the "ENTER" key.





12. Reprogramming will proceed automatically as shown.





13. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start engine and verify normal operation.

* NOTICE
If reprogramming did not complete properly or was interrupted, repeat process using the following procedure.

01/02MY MANUAL REPROGRAMMING

PROCEDURE:

14. Turn ignition key to the "ON" position.





15. Turn Hi-Scan Pro on and select "11. OPTIMA 2.4 01/02MY BATTERY DRAIN" and press the "ENTER" key.





16. Select "02. OPTIMA 2.4D BATTERY DRAIN [ERROR]" and press the "ENTER" key.





17. Select vehicle model year and transaxle type from the menu and press the "ENTER" key.








18. At the prompt, enter your password from the password table according to vehicle model year and transaxle type and press the "ENTER" key.





19. Reprogramming will proceed as shown.





20. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start engine and verify normal operation.

03MY ECM REPROGRAMMING

PROCEDURE:





1. Remove program card from the upper slot on Hi-Scan Pro and insert the reprogramming card.





2. Connect reprogramming adapter to Hi-Scar Pro.

3. Connect 20 pin DLC adapter to reprogramming adapter cable.

4. Connect vehicle power adapter to Hi-Scar Pro.

5. Connect reprogramming adapter power cable to vehicle power adapter.





6. Connect Hi-Scan Pro to under hood DLC located near vehicle battery.

7. Connect vehicle power adapter to vehicle battery.





8. Turn ignition key to the N" position.

9. Turn Hi-Scan Pro on and select "12. OPTIMA 2.4 O3MY BATTERY DRAIN" and press the "ENTER" key.





10. Select "01. OPTIMA2.4D BATTERY DRAIN [AUTO]" and press the "ENTER" key.





11. At the prompt, enter your password "0525" and press the "ENTER" key.





12. Reprogramming will proceed automatically as shown.





13. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start vehicle and verify normal operation.

* NOTICE
If reprogramming did not complete properly or was interrupted, repeat process using the following procedure.

03MY MANUAL REPROGRAMMING
PROCEDURE:





14. Turn ignition key to the "ON" position.

15. Turn Hi-Scan Pro on and select "12. OPTIMA 2.4 O3MY BATTERY DRAIN" and press the "ENTER" key.





16. Select "02. OPTIMA 2.4D BATTERY DRAIN [ERROR]" and press the "ENTER" key.





17. Select vehicle transaxle type from the menu and press the "ENTER" key.








18. At the prompt enter your password from the password table and press the "ENTER" key.





19. Reprogramming will proceed manually as shown.





20. When "REPROGRAMMING COMPLETED" message is displayed, turn ignition key to the "OFF" position and disconnect Hi-Scan Pro from the vehicle. Wait at least 20 seconds, start vehicle and verify normal operation.





ROM ID TABLE:

AFFECTED PRODUCTION RANGE:

2001 - 2003 Optima 4 cylinder models produced before 5/1/03.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: