Campaign SA103 - Replace HEV Battery Cable Terminals
NUMBER 024GROUP Electrical
DATE November 2011
MODEL 2011MY Optima Hybrid (TF HEV)
SUBJECT: SERVICE ACTION: OPTIMA HYBRID (TF HEV) BATTERY CABLE TERMINAL REPLACEMENT (SA103)
This bulletin provides information relating to 12V auxiliary battery Positive (+) and Negative (-) cable terminal replacement on Optima Hybrid vehicles produced from May 01, 2011 to June 30, 2011. Kia is requesting the completion of this Service Action on all affected 2011 MY Optima Hybrid (TF HEV) vehicles prior to delivery. Before conducting the procedure, verify that the vehicle is included in the list of the affected VINs.
*NOTICE
A Service Action is a repair program without customer notification that is performed during the warranty period. Any dealer requesting to perform this repair outside the warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service> Warranty Coverage> Warranty Coverage Inquiry> Campaign Information). Not completed Recall / Service Action reports are available on WebDCS (Consumer Affairs> Not Completed Recall> Recall VIN> Select Report), which includes a list of affected vehicles.
This issue number is SA103.
Service Procedure:
1. Open the trunk.
Remove the battery cover (A). Then locate the auxiliary battery.
WARNING
Caution labels are attached to all the high-voltage components. High-voltage cables and connectors are orange colored. Do not touch any of these high-voltage components, cables or connectors without proper protective gear and training.
Negative (-) Battery Cable Terminal Removal
2. Remove the cable connecting nut (B) and separate the cable from the cable terminal (C).
3. Loosen the cable terminal mounting nut (D) and remove the cable terminal (C).
Positive (+) Battery Cable Terminal Removal
4. Open the terminal cover.
Remove the mounting nut (E) and loosen the battery terminal mounting nut (F).
Remove the terminal plate (G) from the battery terminal.
5. Using the head of a flat screwdriver (H), remove the cable terminal (I) from the terminal plate by pushing the terminal in the direction of the arrow to release from plate's tabs.
6. Remove the cable terminal (I) from the cable (J).
7. Install new Positive (+) battery cable terminal in reverse order of removal.
Install the new Negative (-) battery cable terminal in reverse order of removal.
+/- Battery cable terminal torque specs: 5.8-7.2 lb-ft (7.8-9.8 Nm)