TSBCHA049

GROUP
Chassis
NUMBER
049
MODEL
2011-2013MY
Optima Hybrid
(TF HEV)
DATE
December 2014
TECHNICAL SERVICE BULLETIN
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. Listen to the sound file
below to become familiar with the particular brake noise and, if confirmed, follow the procedure
outlined in this bulletin to resolve the concern.
TF HEV Brake Noise.mp3
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 highvoltage components, cables or connectors without proper protective gear and
training.
File Under: 
Circulate To:
x General Manager

x Service Advisor(s)

x Service Manager

x Parts Manager

x Technician(s) 
x Body Shop Manager  Fleet Repair

Page 2 of 8
SUBJECT:
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
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).
B
A
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 3 of 8
SUBJECT:
5.
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
Remove the first brake line assembly
(C) located between the the Electronic
Stability Control (ESC) Module (D) and
the Master Cylinder (E).
D
E
C
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)
F
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 4 of 8
SUBJECT:
7.
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
Disconnect the Brake Fluid Level
Sensor connector (G).
G
8.
Remove the first mounting location for
the second brake line assembly (I) at
the Master Cylinder (H).
I
H
9.
Continue removing the second brake
line assembly at the Hydraulic Power
Unit (HPU) (J).
J
G
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 5 of 8
SUBJECT:
10.
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
Prior to installation, inspect the
Damping Chamber (L) to make sure
the crush washer (K) is present.
L
K
 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 )
L
M
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 6 of 8
SUBJECT:
12.
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
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)
N
(P): 10.1 ~ 12.3 Ib-ft (13.7~ 16.7 Nm)
O
N
P
13.
Reconnect the Brake Fluid Level
Sensor connector (G) to the reservoir.
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 7 of 8
SUBJECT:
14.
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
Remove the brake pedal jack (Q).
Q
L
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.
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014
Page 8 of 8
SUBJECT:
OPTIMA HYBRID - NOISE DURING BRAKE ACTUATION
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.
HPU NOISE FIX KIT
58670-4R005FFF
1
BRAKE FLUID DOT 3 HD
UM040 CH013
1
Figure
WARRANTY INFORMATION:
Claim
Type
W
Causal P/N
58718 4U000
Qty.
1
N
Code
N29
C
Code
Repair
Description
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
C99
(CHA 049)
Hybrid Brake
System
Procedure
58670F00
1.1
M/H
58670
4R005FFF
1
Note: Use sublet code X1 for reimbursement of brake fluid ($5.11 maximum).
TSB: CHA 049 Optima Hybrid (TF HEV) December 2014