PS520

GROUP
Electrical
NUMBER
PS520
SUBJECT:
MODEL
2017MY~
Optima Hybrid (JF HEV)
Optima Plug-in Hybrid
(JF PHEV)
Niro (DE HEV)
DATE
October 2017
HYBRID POWER CONTROL UNIT 30A DC FUSE
The 2017MY~ Optima Hybrid (JF HEV), Optima Plug-in Hybrid (JF PHEV), and Niro (DE HEV)
vehicles are equipped with a replaceable 30A fuse for the eCompressor. This fuse is easily
accessible under a cover between the power cable connector and inverter cable, as shown
below. However, the housing for the fuse is internally bolted to the HPCU assembly and is only
available as part of the HPCU assembly. Forcibly removing the fuse housing assembly will
result in damaging the internal HPCU terminals which will require replacement of the entire
HPCU assembly and is not covered under Warranty.
Follow the procedure below to inspect and/or replace the fuse, or refer to the “Hybrid Control
System → Hybrid Control System → DC Fuse → Repair procedures” chapter in the applicable
Shop Manual on KGIS.
DANGER
When performing this procedure, follow all EV battery safety precaution procedures
found in the “General Information → General Safety Information and Caution”
chapter in the Shop Manual on KGIS and wear all required Personal Protection
Equipment (PPE). Failure to follow the safety instructions may result in serious
electrical injuries.

Page 1 of 3
Inspection/Replacement Procedure:
1.
Remove the Hybrid Control System
Safety Plug (A) by referring to the
“Hybrid Control System → High Voltage
Shut-off Procedures” chapter in the
applicable Shop Manual on KGIS.
DANGER
A
Failure to follow the High
Voltage Shut-off Procedure may
result in serious electrical
injuries.
Optima Plug-in Hybrid (JF PHEV) shown. Location
of Safety Plug may be different on other vehicles.
2.
Open the hood and remove the air intake
duct (B) (if applicable).
B
3.
Disconnect the power cable (C) and
inverter cable (D).
Page 2 of 3
C
D
4.
Remove the upper three (3) cover
retaining bolts marked () in the photo to
the right and remove the cover. DO NOT
remove the lower fuse housing bolts.

 NOTICE
Removal of the three lower fuse
housing bolts and forcibly
removing the housing assembly
will result in a damaged HPCU
assembly!
DO NOT
REMOVE!
Tightening torque for cover bolts ():
43.2 – 60 in.lb (4.9 – 6.9 N.m,
0.5 – 0.7 kgf.m)
5.
With pliers, remove the plastic cover (E).
E
6.
To inspect the fuse, check the continuity
between ends of the fuse (F).
G
Continuity Specification:
Less than 1Ω (at 68°F, 20°C)
To replace the fuse, remove the two (2)
fuse retaining bolts (G) and remove the
old fuse (F), then install the new fuse.
Tightening torque for fuse bolts (G):
82.8 – 92.4 in.lb (9.3 – 10.4 N.m,
0.95 – 1.06 kgf.m)
7.
Reinstall all removed components in the
reverse order of removal.
8.
Confirm proper
eCompressor.
operation
of
the
Page 3 of 3
F