TSB-ENG166

GROUP
ENG
MODEL
2017MY
Optima (JF HEV/PHEV)
NUMBER
166
DATE
April 2017
TECHNICAL SERVICE BULLETIN
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
This bulletin provides the procedure to inspect the Hybrid Starter Generator (HSG) pulley nut
and, if necessary, replace the HSG assembly on certain Optima JF HEV/PHEV vehicles with a
production range from May 31, 2016 to November 22, 2016, which may exhibit a loose pulley
nut.
 NOTICE
Before conducting this procedure, verify that the vehicle is included in the list of
affected VINs.
For further information and/or additional details about the service procedures, refer
to the applicable Workshop Manual.
File Under: 
Circulate To:
X General Manager

X Service Advisors

X Technicians

X Service Manager

X Parts Manager

X Body Shop Manager  Fleet Repair

Page 2 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
 NOTICE
A Service Action is a repair program without customer notification that is performed
during the warranty period. Any dealer requesting to perform this repair outside the
warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service → Warranty Coverage →
Warranty Coverage Inquiry → Campaign Information). Not completed Recall / Service
Action reports are available on WebDCS (Consumer Affairs → Not Completed Recall
→ Recall VIN → Select Report), which includes a list of affected vehicles.
This issue number is SA289.
Inspection Procedure:
Check the vehicle odometer mileage.

If the mileage is less than 6,500
miles, replace the HSG assembly,
regardless of the paint mark on
the HSG pulley (A). (Refer to the
“Replacement
Procedure”
on
page 3.)
A
TSB:SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 3 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:

If the mileage is more than
6,500 miles,
C
B
o If the paint mark is aligned
(B), no further action is
required, or
o If the paint mark is not
100% aligned (C), replace
the HSG assembly. (Refer
to
the
“Replacement
Procedure” below.)
Replace
OK
Inspection criteria if vehicle
odometer is over 6,500 miles
Replacement Procedure:
DANGER
When performing this procedure, follow all EV battery safety procedures found in the
“Service Materials>>Service Info>>Hybrid Control System>>”General safety
Information and Caution” chapter in the Service Manual, and wear all required
Personal Protection Equipment (PPE).
1.
Before removing the HSG, disconnect
the high voltage circuit.
Follow the appropriate procedure below:
(HEV or PHEV )
HEV Hybrid Connector:
a. Open the trunk.
b. Lift the trunk floor cover.
A
c. Remove the two (2) bolts (A) on
the connector cover.
TSB: SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 4 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
d. Remove the cover (B).
B
e. Disconnect
circuit.
the
high
voltage
PHEV Hybrid Connector:
a. Open the trunk.
b. Lift the trunk floor cover.
c. Remove the two (2) bolts (C) on
the connector cover.
C
TSB:SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 5 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
d. Remove the cover (D).
D
d. Disconnect
circuit.
2.
the
high
voltage
Drain the coolant from the hybrid cooling
system.
(Refer to the “Hybrid Motor System →
Hybrid Motor Assy → Hybrid Starter
Generator (HSG) Repair procedures”
chapter in the applicable Work Shop
Manual.
3.
Remove the drive belt.
TSB: SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 6 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
4.
Disconnect the HSG connector (E) and
remove the wiring from the bracket.
E
5.
Remove the coolant hoses (F) from the
HSG.
F
6.
Disconnect the HSG high voltage cable
connector (G).
G
TSB:SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 7 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
7.
Remove the intake manifold (H).
(Refer to Engine Mechanical System –
“Intake Manifold”).
Tightening Torque:
13.7 ~ 17.4lb-ft (18.6 ~ 23.5N.m,1.9 ~
2.4gf.m)
 NOTICE
8.
H

The four (4) intake manifold
gaskets will be replaced.

The EGR and throttle body
gaskets will be reused.
Remove the HSG mounting nut (I) and
bolt (J).
Tightening Torque:
32.5 ~ 39.8lb-ft (44.1 ~ 53.9N.m, 4.5 ~
5.5gf.m)
I
J
9.
Remove the HSG after removing the
HSG bracket (K).
Tightening Torque:
32.5 ~ 39.8lb-ft (44.1 ~ 53.9N.m, 4.5 ~
5.5gf.m)
K
TSB: SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 8 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
10. Install the new HSG.
11. Re-assemble all the other parts in the
reverse order of removal.
12. Reconnect the high voltage circuit.
13. Refill the hybrid cooling system with
coolant and bleed the air from the hybrid
cooling system using the KDS.
(Refer to Hybrid Motor Cooling System –
“Coolant.”)
 NOTICE
Visually verify that the coolant
is circulating in the HPCU
reservoir.
14. Perform the engine clutch/motor resolver
adaptation using the KDS.
15. Confirm proper HSG operation by
running the engine and checking for
DTCs.
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Optima (JF HEV/PHEV)
May 31, 2016 to November 22, 2016
TSB:SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017
Page 9 of 9
SERVICE ACTION: HYBRID STARTER GENERATOR (HSG)
PULLEY NUT INSPECTION AND/OR HSG REPLACEMENT (SA289)
SUBJECT:
REQUIRED PARTS:
Part Name
Part Number
Figure
HSG Assembly
37390 2E960QQK
Intake Manifold
Gasket
28313 2E000QQK
Qty.
1
N/A
4
WARRANTY INFORMATION:
Claim Causal
N
C
Qty.
Type
P/N
Code Code
0
V
37390
2E960
N99
0
C99
Repair
Description
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
HSG Pulley Nut
Inspection
160144R0
0.2
M/H
N/A
0
373902E960QQK
1
28313
2E000QQK
4
HSG Pulley Nut
Inspection and
HSG Assembly
Replacement
160144R1
2.1
M/H
TSB: SA289 Optima (JF HEV/PHEV) 2017MY Optima April 2017