2018 Kia Optima Plug-In Hybrid EXFACTORY OEM SERVICE PROCEDURE

Connector Inspection Procedure

  1. Handling of Connector
    1. Never pull on the wiring harness when disconnecting connectors.
      G12347210Courtesy of KIA MOTORS AMERICA, INC.
    2. When removing the connector with a lock, press or pull locking lever.
      G12347211Courtesy of KIA MOTORS AMERICA, INC.
    3. Listen for a click when locking connectors. This sound indicates that they are securely locked.
      G12347212Courtesy of KIA MOTORS AMERICA, INC.
    4. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side.
      G12347213Courtesy of KIA MOTORS AMERICA, INC.
    5. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side.
      G12347214Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Use a fine wire to prevent damage to the terminal.
    • Do not damage the terminal when inserting the tester lead.
  2. Checking Point for Connector
    1. While the connector is connected:

      Hold the connector, check connecting condition and locking efficiency.

    2. When the connector is disconnected:

      Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.

      Visually check for rust, contamination, deformation and bend.

    3. Check terminal tightening condition:

      Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.

    4. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
    G12347215Courtesy of KIA MOTORS AMERICA, INC.
  3. Repair Method of Connector Terminal
    1. Clean the contact points using air gun and/or shop rag.
      NOTE: Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
    2. In case of abnormal contact pressure, replace the female terminal.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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