GROUP

Electrical

MODEL

Optima Hybrid
(TF HEV)

NUMBER

DATE

044

January 2013

TECHNICAL SERVICE BULLETIN
SU BJECT:

HIGH-VOLTAGE BATIERV ORDERING AND RETURN PROC EDURE

This bulletin outli nes the ordering and return procedure for high-voltage Lithium-ion batteries for Optima
Hybrid vehicles (hereafter referred to as "high-voltage batteries" or HVBs). Every Kia-approved hybrid
dealership's parts and service departments should follow these procedures to ensure the fastest
handling time and to minimize the possibility of charge-backs.

'

Limitations on High Voltage Battery Orders
Non-approved hybrid dealerships cannot order HVBs or be paid by warranty for repairs performed on
hybrid components.
HVBs cannot be ordered except as direct replacements for damaged or failed HVBs.
In the case of out-of-warranty or collision-damaged HVBs, evidence of the failure or damage must be
submitted via a Tech Line case. A core return is required in all cases.

Shipping and Handling Regulations
Pursuant to federal law, all shipments of HVBs, to or from the dealer, must be shipped by ground
service. Air shipments are not allowed.
•

Anyone who receives, packs, ships, or otherwise handles HVBs may need to be hazardous materials
(HazMat) certified, as required by the U.S. Department of Transportation.
It is the dealership's responsibility to ensure that its team members are appropriately certified and
follow all laws and regulations related to this and other HazMat components on Kia vehicles.

File Under:

Circulate To :

[Kl General Manager

00 Service Advisor(s) [K

Technic ian(s)

[X] Service Manager

Parts Manager

!X] Body Shop Manager

Fleet Repair

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ORDERIN?lf.X~p RETURN PROCEDURE
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Ordering Procedure :
The service department should follow this procedure when requesting a battery.
1. Use GOS to scan for OTCs.
a. If an HVB OTC (P1 870, P187 4, or P1896) is found , save screenshots of the OTC search
results . This can be achieved with 1-2 screenshots.
b. Save the screenshots of each OTC's Freeze-Frame Data . Th is can be done with 2
screenshots per OTC.
c. Select the BMS system and save screenshots of Current Data. This can be done with 5 screenshots.

Screenshot examples are provided on the last page of this document.
2. Create a Tech Line web case , and include the following items in the initial message:
a. Describe the customer complaint and what portion of the complaint was duplicated or
confirmed .
b. Identify (in the case notes) the problem cells from the FFO or BMS Current Data.
c. Upload all screenshots to the case .
3. A Tech Line representative will review these details and recommend either HVB replacement
or another action.
4. If Tech Line recommends HVB assembly replacement, the dealership service department should
contact its OPSM for a PWA and place a parts order for the HVB assembly, Battery Management
System control module (BMS), and any other components that are recommended by Tech Line (for
non-warranty repairs, evidence of battery failure or damage must be submitted via Tech Line case).
The HVB will appear to be on backorder; this is normal. The order will be reviewed by Mobis Parts
America and Kia Motors America with two possible outcomes:
a. If approved , the order wi ll be al located and shipped via ground carrier.
b. If not approved, the dealership will be contacted and informed of the appropriate actions to take.

*NOTICE
HVB packs are shipped from California, and transit times will vary from 1 to 5 business
days from shipment date in the contiguous United States. Transit time of shipments to
dealers in Hawaii or Alaska w ill require additional t ime.

*NOTICE
Every HVB replacement also requ i res installation of a new BMS (includ ing
replacements due to collisio n damage).

TSB : ELE 044

Optima Hybrid (TF HEV)

January 2013

Page 3 of 4
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Return Procedure:
The parts department should follow this procedure when receiving a replacement HVB and when
returning the original (core) HVB.

1. When the replacement HVB ships , KMA Warranty Department will supply instructions ,
including a bill of lading and the emergency response document via email to the dealership
parts department.
2. When receiving the replacement HVB, inspect the wooden shipping crate of the replacement
HVB for damage. If it was damaged in shipment, be certain to note this on the receiving
document, and contact the Parts Hotline to request a new crate for the HVB.
3. Care must be taken when unpacking the replacement HVB to not damage the wooden crate .
Damage caused by the dealer will be the dealership's responsibility. Make sure to retain all
packaging materials for reuse.
4. Package the return HVB in the same manner as the replacement HVB was received.
5. If the Battery Management System control module (BMS) was replaced in the same repair
as the HVB, the two components must be returned in the same shipment, unless otherwise
instructed by KMA To do this , install the BMS into its place on the HVB assembly. Except for
the BMS, no other components should be returned with the HVB assembly (e.g., HVB fan) .
6. Follow all federal requirements for preparing the HazMat shipment. KMA cannot legally
accept inappropriately pac kaged , marked, or mislabeled HazMat shipments. Situations
arising from these and other errors are time-consuming to resolve and may result in fines
to the dealer by various government entities. In addition, if these situations cause financial
losses to KMA, KMA may seek reimbursement for any added processing costs or delays.

See next page for example of GDS Screen Capture Process

TSB: ELE 044

Optima Hybrid (TF HEV)

January 2013

Page 4 of 4

SUBJECT:

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ORDERIK.Jr~~~ RETURN PROCEDURE
GOS Screen Capture Process (BMS Current Data Shown as an Example) :

Click on the camera icon in the upper-right corner of the active GOS screen, select "Entire GOS
Area ," make sure that there is a check mark next to "Include Vehicle Info," and cl ick on "Send to
File." Remember or write down the file path for the screenshots, and name the screenshot files so
that it is clear which should be uploaded to the Tech Li ne case.
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OPTI"'.A H\'BRIDITT l