GROUP

MODEL

Service Campaign

2013-2016MY
Optima Hybrid (TF HEV)

NUMBER

DATE

SC269 (Rev 1, 08/15/2024)

July 2023

VOLUNTARY SERVICE CAMPAIGN
HIGH-VOLTAGE BATTERY SAFETY PLUG FUSE
SUBJECT:

INSPECTION AND REPLACEMENT (SC269)
 NOTICE

This bulletin has been revised to include additional information. New/revised sections of this
bulletin are indicated by a black bar in the margin area.
This bulletin provides information to inspect and, if necessary, replace the High Voltage Battery (HVB) Safety
Plug Fuse Assembly or Main Fuse on 2013-2016MY Optima Hybrid (TF HEV) vehicles produced from
September 27, 2012 through July 22, 2015. The high-voltage fuse in the subject vehicles may have been
replaced with an improper non-OEM aftermarket fuse by third-party repair facilities. A fuse of incorrect
capacity may experience a shortened service life, which may result in illumination of the “Hybrid System
Warning” and/or “Check Engine Light,” followed by a no-start condition. If an improper non-OEM aftermarket
fuse is installed, it may fail and result in a fire. Follow the procedure outlined in this publication to inspect and,
if necessary, replace the HVB Safety Plug Fuse Assembly or Main Fuse. Before conducting the procedure,
verify that the vehicle is included in the list of affected VINs.

 NOTICE
Repair status for a VIN is provided on KDealer+ (Service → Warranty Coverage → Warranty
Coverage Inquiry → Campaign Information). Not completed Recall / Service Action reports are
available on KDealer+ (Consumer Affairs → Not Completed Recall → Recall VIN → Select Report),
which includes a list of affected vehicles.

A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Kia America, Inc. Internal Use Only

Page 2 of 6
SUBJECT:

HV BATTERY SAFETY PLUG FUSE INSPECTION AND REPLACEMENT (SC269)

Flowchart:

Vehicle In

Is safety plug
main fuse resistance
over 1 ?

YES

NO

Inspect Fuse Type:
Replace Fuse
w/Genuine 150A

Genuine
125A
(NG)

•
•
•

Genuine 150A
Genuine 125A
Non-Genuine Fuse

Non-Genuine
Fuse
(NG)

Genuine
150A
(OK)

Genuine 150A
Installed

Vehicle Out

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SC269 (Rev 1) Optima Hybrid (TF HEV)
July 2023
Kia America,
Inc. Internal Use Only

Replace the
Safety Plug Assembly
(Black or Green Option)

Page 3 of 6
SUBJECT:

HV BATTERY SAFETY PLUG FUSE INSPECTION AND REPLACEMENT (SC269)

Inspection & Replacement Procedure:
1.

Disconnect the auxiliary 12V battery negative
(-) cable located in the rear cargo area.

DANGER
Failure to follow the High Voltage
Shut-off Procedure may result in
serious electrical injuries.

2.

Open the High Voltage Battery (HVB) safety
plug service cover in the rear cargo area.

WARNING
Be sure to read and follow the
“General

Safety

Information

and

Caution” information on KGIS when
working with a High Voltage system.
Failure to do so can result in serious
electrical injuries.
3.

A

Unlock the lever hook (A).

B

Pull down on the lever (B).
Remove the safety plug (C).

C
4.

Using a flathead screwdriver, remove the
safety plug cover (D) to expose the High

D

Voltage (HV) main fuse (E).
Note: OPEC 125A/150A is the Kia genuine fuse.

E
D

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SC269
(Rev 1) Optima Hybrid (TF HEV) July 2023
Kia America, Inc. Internal
Use Only

Page 4 of 6
SUBJECT:

5.

HV BATTERY SAFETY PLUG FUSE INSPECTION AND REPLACEMENT (SC269)
Using a multimeter, measure the HV main fuse
resistance (in Ohms).
•

Resistance is 1Ω or less (OK), proceed
to step 6.

•

Resistance is over 1Ω (NG), replace the
HV main fuse with a new 150A fuse,
then proceed to step 7.

6.

Inspect existing Genuine Kia (Opec) amperage
rating of the HV main fuse installed and/or if
the

fuse

has

been

replaced

with

an

aftermarket (non-genuine Kia) fuse.
•

Genuine Kia (Opec) 125A HV main fuse
present (NG): Replace the 125A main
fuse with a new 150A, then proceed to
step 7.

•

Genuine Kia (Opec) 150A HV main

Genuine Fuse (150A)

fuse present (OK): No further action is
required. Proceed to step 7.
•

A ‘non-genuine Kia’ HV main fuse is
present (NG): Replace the Safety Plug
Fuse Assembly (150A, Black or Green
option, as applicable), then proceed to
step 7.
Non-Genuine 150A Fuse

7.

Reinstall all removed parts in the reverse order
of removal.

8.

Confirm normal vehicle operation.

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SC269 (Rev 1) Optima Hybrid (TF HEV)
July 2023
Kia America,
Inc. Internal Use Only

Page 5 of 6
SUBJECT:

HV BATTERY SAFETY PLUG FUSE INSPECTION AND REPLACEMENT (SC269)

AFFECTED VEHICLE RANGE:
Model

Production Date Range

Optima Hybrid (TF HEV)

September 27, 2012 to July 22, 2015

REQUIRED TOOL:
Tool Name

Part Number

Figure

Comments

Multimeter

N/A

N/A

Locally Sourced

REQUIRED PART:
Part Name

Safety Plug Fuse Assembly*
(Black Locking Hook)

Safety Plug Fuse Assembly*
(Green Locking Hook)

High Voltage Main Fuse

Part Number

Figure

Qty.

37586 4R000ASQQK

1

37586 4R002QQK

1

375F2 4R150QQK

1

Note: The replacement part numbers will require a VIN entry for parts ordering. This repair is an inspect and
if necessary, replace. DO NOT order these parts for stocking purposes, related to this Campaign. Supply is
very limited. Until supply stabilizes, please confirm part availability before scheduling customers. Please be
sure to expedite warranty claim filing. *When replacing the Safety Plug Fuse Assembly, DO NOT ORDER the
HV Main Fuse as the fuse is included with a new Safety Plug fuse assembly.

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SC269
(Rev 1) Optima Hybrid (TF HEV) July 2023
Kia America, Inc. Internal
Use Only

Page 6 of 6

HV BATTERY SAFETY PLUG FUSE INSPECTION AND REPLACEMENT (SC269)

SUBJECT:

WARRANTY INFORMATION:
N Code: N99 C Code: C99
Claim
Type

Causal P/N

Qty.

Repair

Labor Op

Op

Replacement

Description

Code

Time

P/N

(SC269)
Fuse Inspection (OK)

230041R3

(Genuine Fuse 150A)
(SC269)
Fuse Inspection (NG)

230041R0

+ Fuse Replacement
R

37586 4R002

0

0.2
M/H

0.3
M/H

(Non-genuine Fuse) +

N/A

0

375F2 4R150QQK

1

37586

(SC269)
Fuse Inspection

Qty.

230041R1

0.3
M/H

Safety Plug Replacement

4R002QQK
or

1

37586
4R000ASQQK

(SC269)
Fuse Inspection
(Genuine Fuse 125A)

230041R2

0.3
M/H

375F2 4R150QQK

1

+ Fuse Replacement

Note: Refer to Warranty Bulletin 2023-20 for claim submission procedures. Manually enter sublet code ‘X2’
for reimbursement of one roundtrip rideshare expense or up to three (3) days of rental expense, with
supporting documentation for Fuse and Safety Plug Replacement only.

 NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference
SC269 when accessing the KDealer+ system.

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: SC269 (Rev 1) Optima Hybrid (TF HEV)
July 2023
Kia America,
Inc. Internal Use Only