Noise During Brake Actuation – 2011-2013 Kia Optima Hybrid

2014-049

 

SUBJECT:

OPTIMA HYBRID – NOISE DURING BRAKE ACTUATION

 

This bulletin provides information to address a brake noise concern on some Optima Hybrid (TF HEV) vehicles, produced from February 15, 2011 through December 8, 2013, which may exhibit a “squeaking” and/or “honking” noise when applying the brakes rapidly. Click on the link below to listen to the sound file in order to become familiar with the particular brake noise and, if confirmed, follow the procedure outlined in this bulletin to resolve the concern.

 

 

Service Procedure:

1. Record the customer’s radio presets before performing the procedure.
2. Disconnect negative (-) terminal from the battery.

 

3. Use a brake pedal jack to push and hold the brake pedal down.

 

4. Open the hood and remove the air duct (A) and air cleaner box (B).

 

5. Remove the first brake line assembly (C) located between the the Electronic Stability Control (ESC) Module (D) and the Master Cylinder (E).

 

6. Install a new brake line assembly (F) between the ESC Module and the Master Cylinder, as shown.

Tightening torque:
13.7 ~ 16.6 Ib-ft (18.6 ~ 22.6 Nm)

 

7. Disconnect the Brake Fluid Level Sensor connector (G).

 

8. Remove the first mounting location for the second brake line assembly (I) at the Master Cylinder (H).

 

9. Continue removing the second brake line assembly at the Hydraulic Power Unit (HPU) (J).

 

10. Prior to installation, inspect the Damping Chamber (L) to make sure the crush washer (K) is present.

*NOTICE 

If the crush washer (K) is misplaced, order P/N 17512-10000.

 

 

11. Install the Damping Chamber (L) onto the Hydraulic Power Unit (HPU) (M), as shown.

Tightening torque:
25.3 ± 3.6 Ib-ft (34.3 ± 4.9 Nm )

 

 

12. Install the second brake line assembly (N) between the Master Cylinder (O) and the Damping Chamber (P) on the HPU (refer to step 9).

Tightening Torque

(O): 21.7 ~ 25.3 Ib-ft (29.4 ~ 34.3 Nm) 

(P): 10.1 ~ 12.3 Ib-ft (13.7~ 16.7 Nm)

 

 

13. Reconnect the Brake Fluid Level Sensor connector (G) to the reservoir.
14. Remove the brake pedal jack (Q).

 

15. Perform the HEV brake bleed procedure per the applicable workshop manual on KGIS.
16. Reinstall all removed components by reversing the order of removal.
17. Reconnect the Negative (-) terminal to the battery.

 

18. After performing the brake bleed   procedure, perform the PTS Calibration Test using GDS.

 

19. After calibration is complete, verify proper brake operation and confirm the  noise is no longer present.
20. Restore the customer’s radio presets, as recorded on step 1.

 

AFFECTED VEHICLE PRODUCTION RANGE:

Model	Production Date Range
Optima Hybrid (TF HEV)	From February 15, 2011 through December 8, 2013

 

PART INFORMATION:

Part Name	Part Number	Qty.	Figure
HPU NOISE FIX KIT	58670-4R005FFF	1
BRAKE FLUID DOT 3 HD	UM040-CH013	1