ECO plug in 2022 MQ4 Sorento PHEV

Identification / Recognition

Initial Response: Identify, Immobilize and Disable
The following procedures should be used whenever you are dealing with a Sorento PHEV at an emergency scene. However, all operations should be consistent with your department’s standard operating procedures, guidelines, and any applicable laws. When a PHEV is damaged in a crash, the high-voltage safety systems may have been compromised and present a potential high-voltage electrical shock hazard. Exercise caution and wear appropriate personal protective equipment (PPE), including high-voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings.

Identify

• The Sorento PHEV is a hybrid electric vehicle. Emergency responders should respond to emergency scenarios involving the Sorento PHEV accordingly, exercising extreme care and caution to avoid contact with the high-voltage system within the vehicle.

Identifying a Kia Sorento PHEV

Orange-Colour Cable
Orange colour cables run under the floor of the vehicle and under the hood. When opening the hood, the orange colour cable identifies a PHEV.

Charging Port

• The charging port is located on the side of the vehicle.

  Note: The doors must be unlocked to open the charge port door.

How to open the charging port

1. Press the unlock door button, depress the brake pedal, and apply the electric parking brake (EPB).
2. Turn OFF all switches, move the shift dial to P (Park), and turn off the vehicle
3. Open the charging inlet door by pressing rear centre edge of the charging inlet door.

Unlock charging door in emergency

• Charging door can be open even if the battery is discharged. (Push the charging port)
• The charging cable may not be disconnected when foreign materials enter the cable or the cable is encrusted with ice.
• If this happens, open the cover(1) on the right side of the luggage room and pull the emergency cable(2) lightly 2 to 3 times.

VIN Label

The VIN (Vehicle Identification Number) identifies a plug-in hybrid car with an “H” displayed in the 8th position, as shown in the picture below.
The VIN can be found:

1. VIN Plate can be seen through the windshield from outside.
2. On the vehicle certification label attached to the driver’s side centre pillar.
3. Underneath the front passenger seat (or driver seat).
   

Sorento PHEV Cluster Instrument Panel

The Sorento PHEV Cluster Instrument Panel displays PHEV specific features such as highvoltage battery SOC (State of Charge) as highlighted below.

1. Power Gauge
2. Speedometer
3. Hybrid Battery SOC Gauge
4. Fuel Gauge
5. LCD Display
6. Warning and Indicator Lights

Charge Status Indicator

You can check the charging status at the outside of vehicle when charging or using the high-voltage battery. The colour of lights illuminated indicates the charge level of the battery.

Immobilization / Stabilization / Lifting

Immobilization

The next step is to immobilize the vehicle to prevent any accidental movement that can endanger response personnel or civilians. When the Sorento PHEV is damaged in a crash, the vehicle may appear to be shut off, even when it actually is not, due to a lack of enginesounds. When the “READY” mode light is illuminated on the Instrument Panel, the vehicle can move silently using the electric motor. Responders should approach the vehicle from the sides and stay away from the front or rear as they are potential paths for vehicle movement. Be sure to immobilize the vehicle in the following manner.

Vehicle Stabilization

Use standard stabilization (lift) points, as shown beside. Always be sure to connect to a structural component of the vehicle and avoid placing cribbing under high-voltage cables, and other areas not normally considered acceptable.

• When installing a block or jack, avoid high-voltage cable, battery, and fuel system.
• If high-voltage components or cables are exposed, do not place any support on them.

Disable Direct Hazards / Safety Regulations

The final step in the initial response process, conducted after immobilizing the vehicle, is to disable the vehicle, its SRS components, and the high- voltage electrical system. To prevent current flow through the system, use one of the following procedures to disable the vehicle.
*In case of emergency

Disabling the System – Smart Key System and “POWER” START/STOP Button

1. Confirm the status of the light on the instrument panel. If the READY light is illuminated, the vehicle is ON.
   a) If the READY light is NOT illuminated, the vehicle is off. Do not push the “POWER” START/STOP button because the vehicle may start (go into READY mode).
   b) To turn OFF the system, press the ‘P’ (Park) button on the rotary shifter dial, and press the POWER button.

Without depressing the brake pedal
**** Pressing POWER button| Vehicle condition
---|---
One time| Electrical accessories are operational
Two times| The warning lights can be checked before the vehicle is started.
Three times| Off

While depressing the brake pedal

2. If necessary, lower the windows, unlock the doors, and open the tailgate as required, before disconnecting the 12V battery. Once the 12V battery is disconnected, power controls will not operate. (Refer to below “4. – c” for 12V battery disconnection.)
3. Before disconnecting the 12V battery, remove the smart key at least 2 metres away from the vehicle to prevent accidental restart.
4. Follow the procedure below to remove the service interlock connector and disable the high-voltage battery:
   a) Open the luggage mat (A).

b) Remove the auxiliary battery service cover (A).

c) Disconnect the auxiliary 12V negative (-) battery terminal (A) after loosening the nut.

d) Disconnect the service interlock connector (A).

Disabling the System – IG (Ignition) Fuse Removal

1. Open the hood.

2. Remove the engine room fuse box cover.

3. If necessary, lower the windows, unlock the doors, and open the tailgate as required, before disconnecting the 12V battery (located in the left side of the engine room). Once the 12V battery is disconnected, power controls will not operate.

4. In the event the vehicle is unable to be disabled using the “Power” START/STOP Button, using the fuse puller located in the engine room fuse box, pull both the IG1, IG2 fuse from the engine room fuse box. If the IG fuses cannot be located, pull out all of the fuses and relays in the fuse box.

5. Disconnect the 12V battery and disable the interlock cable by referring to page 11.
   If previously mentioned methods of disabling the vehicle’s system are unsuccessful, any emergency procedures involving the PHEV vehicle may cause the accidental deployment of undeployed airbags and electric shock from high- voltage components.

Electrocution Risk

• Before engaging in any emergency response procedures, ensure the vehicle is disabled and wait 5 minutes to allow the capacitor in the high-voltage system to discharge to avoid electrocution.
  

• Exposed cables or wires may be visible inside or outside the vehicle. Never touch the metal chassis wires, cables, connectors, or any electric components before disabling the system.
  

Failure to follow these instructions will lead to serious bodily injury or death by electrocution.

Access to the Occupants

Extraction Operations

The Sorento PHEV is a plug-in hybrid electric vehicle. Because of the high- voltage components contained therein, first responders should pay special attention when they extract occupants in the car. Before performing any extraction operations, the first responders should “Identify, Immobilize and Disable” the vehicle as discussed in sections on emergency procedures.

Vehicle Stabilization

Use standard stabilization (lift) points, as shown beside. Always be sure to connect to a structural component of the vehicle and avoid placing cribbing under high-voltage cables, and other areas not normally considered acceptable.

Extraction Tools and Procedure

When responding to an incident involving a Sorento PHEV, we recommend that the first responders follow their organization’s standard operating procedures for dealing with vehicle emergencies.
When the first responders cut the vehicle, they should always pay special attention to the airbag system, orange-coloured high-voltage cables, and other high-voltage components so that the parts are not damaged and to prevent a risk of explosion or electrocution.

Location of Ultra-High Strength Steel

In these images, high-strength steel is used in the areas coloured in blue and ultra-highstrength steel is used in the red-coloured areas. Depending on the tools used, ultra-highstrength steel can be challenging or impossible to cut. If necessary, use a workaround technique.

Occupants Rescue Guide

| Supplemental Restraint System Control Module (SRSCM)| | Airbag| | Airbag Inflator
---|---|---|---|---|---
| High-Voltage Cable| | Seat Belt Pretensioner| | Air-Conditioning Line
| Service Plug| | 12V Battery (-) Connector| | Ultra-High Strength Steel
| High-Voltage Battery| | Air-Conditioning Component| | Gasoline Fuel Tank & Line
| OBC (On-Board Charger)| | 12V Battery| | High-Voltage Charge Port

Stored Energy / Liquid / Gases / Solids

High-Voltage System

High-Voltage System

Motor
The electric motor of the PHEV converts electrical energy into motive force with a max. power of 59.3 HP (44.2 kW) and max. torque of 195 lb-ft (264 Nm).

HPCU
The HPCU includes an Inverter and LDC (Low Power DC-DC Converter) in one housing. The inverter converts DC to AC to supply electricity to the motor. It also converts AC to DC to charge the high-voltage battery. The LDC converts high voltage electricity to 12 V to charge the 12V auxiliary battery.

PHEV High-Voltage Battery
The HV lithium-ion polymer battery supplies and stores electric energy to the traction motor and it is a lithium-ion polymer battery with specifications: 360V / 38.3Ah / 13.8kWh.

HSG (Hybrid Starter Generator)
The HSG restarts the engine in the ICE/HEV modes, and also charges the high- voltage battery while driving, as this is the generator for hybrid vehicle.

On-Board Charger (OBC)
The OBC is the battery charging equipment that converts external AC to DC to charge the high-voltage battery.

High-Voltage Orange Cabling

The high-voltage cabling is orange, per Society of Automotive Engineers (SAE) standards. Cables run under the floor of the vehicle and connect the high- voltage battery to the HPCU, Motor, LDC, Inverter, OBD, A/C compressor and other high-voltage components located towards the front of the vehicle.

The presence of orange cables under the hood, in the under-floor battery compartment, or HV cables under the car, identifies the vehicle as a PHEV vehicle.

High-Voltage Cables

• Never cut or disconnect the high-voltage orange cabling and connectors without first disabling the HV system. (Refer to page 11.)
  

• Exposed cables or wires may be visible inside or outside the vehicle. Never touch the metal chassis wires, cables, connectors, or any electric components before disabling the system.
  

Failure to follow these instructions will lead to serious bodily injury or death by electrical shock.

Fuel (Gasoline)

In Case of Fire

Firefighting Operations

Strict precautions must be taken while conducting firefighting operations due to following reasons:

• Lithium-ion polymer batteries contain gel electrolyte that can vent, ignite, and produce sparks when subjected to temperatures above 300°F.
• Vehicle may burn rapidly with a flare-burning effect.
• Even after the high-voltage battery fire appears to have been extinguished, renewed, or delayed fire can occur.
• Use a thermal imaging camera to ensure the high-voltage battery is completely cooled before leaving the incident.
• Always advise second responders that there is a risk of the battery re-igniting.
• In a fire, submersion or a collision that has compromised the high-voltage battery, always store it in an open area with no exposures within 50 feet.
• A burning battery could release hydrogen fluoride, carbon monoxide, and carbon dioxide gases. Use NIOSH/MSHA approved full-face self-contained breathing apparatus (SCBA) with full protective gear. Even if the high-voltage battery pack is not directly involved in a vehicle fire, approach the vehicle very carefully.

Extinguishers

• Small fires that do not involve the high-voltage battery should be extinguished using an ABC fire extinguisher. (ex. Fire caused by wiring harnesses, electrical components, etc.)
• Do not attempt to extinguish fires that involve the high-voltage battery with small amounts of water as this can result in electrocution. Fires that involve the high-voltage battery should be extinguished using large amounts of water (Max 100,000 litres) to cool the high-voltage battery. Fire fighters should not hesitate to pour larger amounts of water on the vehicle in such scenarios. Make sure the battery is fully cooled to avoid fire reignition.

How to Deal with the Situation

• To be used if electrolyte solution leakage or damage to the high-voltage battery casing is observed.

Vehicle Fire

• Use a large volume of water (max. 100,000 litres). Water must cool down the battery.

• If water is applied directly onto the high-voltage battery module inside the casing, it will better cool the battery. (But never attempt to penetrate the HV battery or its casing to apply water.)

• Putting water into the high-voltage battery can be difficult due to the battery case.

• Put water through the hole that might be made due to the accident or fire.

High-Voltage Battery Damage and Fluid Leaks

If electrolyte solution leakage or any damage to the lithium-ion battery casing is observed, the first responders should attempt to neutralize the battery by applying a large volume ofwater to the battery pack while wearing appropriate Personal Protective Equipment (PPE).
The neutralization process helps stabilize the thermal condition of the battery pack but does not discharge the battery.

• Do not put any smoke, spark, flame around the vehicle.
• Do not touch or step on the spilled electrolyte.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use soil, sand, or a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.

Electrolyte Irritation

The high-voltage battery contains electrolyte solution. To avoid exposure to electrolyte solution and serious personal injury, always wear appropriate solvent resistant PPE (Personal Protective Equipment) and SCBA (Self-Contained Breathing Apparatus).

• Electrolyte solution is an eye irritant. In the event of contact with eyes, rinse with plenty of water for 15 minutes.
  

• Electrolyte solution is a skin irritant. Therefore, in the event of contact with skin, wash off with soap.
  

• Electrolyte liquid or fumes coming into contact with water will create vapours in the air from oxidization. These vapours may irritate skin and eyes. In the event of contact with vapours, rinse with plenty of water and consult a doctor immediately.
  

• Electrolyte fumes (when inhaled) can cause respiratory irritation and acute intoxication Inhale fresh air and wash mouth with water. Consult a doctor immediately.

High-Voltage Battery Re-ignition by Stranded Energy

Damaged cells in the high-voltage battery can experience thermal runaway* and re-ignition. To prevent re-ignition, the first responder and second responder need to be aware of the risk of stranded energy** which remains in the damaged cells and can lead to re-ignition.

*Thermalrunaway: The originating cause of thermal runaway is generally short-circuiting inside a battery cell and a resulting increase in the cell’s internal temperature. Battery produces heat with thermal runaway, and it can spread from one battery cell to many cells, in a domino effect.

Strandedenergy:** Energy remains inside any undamaged battery cells after the accident. Stranded energy can cause a high-voltage battery to reignite multiple times after a fire has been extinguished.

How to Prevent Re-ignition (Mitigating Stranded Energy Risk)

1.  12V battery (-) terminal disconnection (To depower battery management system)
2.  High-voltage shutoff
   *Refer to page 11
3.  Discharging the high-voltage battery
   *Refer to pages 27-28

In Case of Submersion

Submerged or Partially Submerged Vehicles

Some emergency responses can involve a submerged vehicle. The Sorento PHEV does not have high-voltage components on the vehicle’s body or framework. It is safe to touch the vehicle’s body or framework if there is no severe damage to the vehicle, whether it is in water or on land.

If the vehicle is submerged or partially submerged, remove the vehicle from the water before attempting to disable the vehicle. Drain the water from the vehicle. Use the methods described in pages 9-13 to disable the vehicle.

Then, discharge the battery by referring to pages 27-28.

• If severe damage causes high-voltage components to become exposed, responders should take appropriate precautions and wear appropriate insulated personal protective equipment.
• Do not attempt to remove an interlock connector while the vehicle is in water.

Failure to follow these instructions can lead to death or serious injury by electrocution.

Towing / Transportation / Storage

Towing and Transportation

In the event of an accident, the high-voltage system must be disabled. The interlock connector must be removed from the high-voltage battery according to one of the methods described in pages 9-13 to disable the vehicle.

Towing the Sorento PHEV Vehicle is not different from towing a conventional AWD vehicle.

If emergency towing is necessary, we recommend having it done by an authorized Kia dealer or a commercial tow-truck service. Proper lifting and towing procedures are necessary to prevent damage to the vehicle.

The use of wheel dollies or flatbed is recommended.

• Do not tow with sling-type equipment. Use wheel lift or flatbed equipment.
• _Never tow the vehicle with the front wheels on the ground (forward or backward), as this may cause fire or damage to the motor.

_

Storage of Damaged Vehicle with the Damaged Battery (Discharge)

• Drain fluids and water, then disconnect the negative (-) terminal of the 12 V battery.

• In addition, remove the water used for the extinguisher inside the battery or vehicle, then remove the interlock connector from the high-voltage battery before storing a damaged vehicle.

• Place the vehicle in an open space away from any structure, vehicle, or building.

• Then, keep an eye on the vehicle until the discharging procedures are completed.

• If the battery can be removed from the vehicle by moving the vehicle on the lift, remove
  and discharge the battery. (Refer to the next page.)

• If the battery can’t be removed, set the water pool, and pour water until the entire battery
  is submerged.
  # Water pool condition: tap water or pond water that does not contain salt.

• Maintain this water level for at least 90 hours.

• Then, put salt into the water pool to make 3.5 % salt water.

• Wait for additional 48 hours in salt water.

• Drain the water by removing the BMU service cover.

Battery Discharging

• DO NOT USE SALT WATER for the first step.
• A large volume of flammable hydrogen gas can be generated in salt water due to electrolysis.
• After submerging the vehicle in pure water for at least 90 hours, put salt in the water pool.
• Do this procedure if there is a possibility of re-ignition.
  

Damaged Battery Storage

• To be stored safely, the damaged battery must be discharged.

• If the battery can be removed from the vehicle, discharge the battery to prevent reignition.

• Extinguish all smoke, spark, flame around the vehicle.

• Electrolyte solution is a skin irritant.

• Do not touch or step on the spilled electrolyte.

• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use soil, sand, or a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.

• Prepare water that does not contain salt such as tap water or pond water.

• Leave the battery in water for at least 90 hours.

• Then, put salt in water to make 3.5% salt water.

• Wait for additional 48 hours in salt water.

• Take out the battery from the container and dry it.

Important Additional Information

Emergency Starting

Jump Starting
Do not attempt to jump start the high-voltage battery, as it cannot be jump- started. In case of full discharge of the high-voltage battery, the vehicle must be towed as mentioned on the previous page.

In case the 12V auxiliary battery is discharged, connect a starting device to the jump terminal in the engine room as you would any 12V battery (see image). Refer to the “Emergency Starting” section of the Owner’s Manual for additional information. Connect jumper cables in the order shown in the image and disconnect in reverse order.

Do not attempt to jump start the Sorento PHEV high-voltage battery.
Failure to follow these instructions will lead to serious bodily injury or death by electrical shock.

Jump Starting Procedure

1. Make sure the booster battery is 12-Volt and that its negative terminal is grounded.
2. If the booster battery is in another vehicle, do not allow the vehicles to come in contact.
3. Turn off all unnecessary electrical loads.
4. Connect the jumper cables in the exact sequence shown in the illustration. First connect one end of a jumper cable to the positive terminal of the fuse box (1), then connect the other end to the positive terminal on the booster battery (2). Proceed to connect one end of the other jumper cable to the negative terminal of the booster battery (3), then the other end to a solid, stationary, metallic point away from the fuse box (4).

Airbag system (SRS : Supplemental Restraint System)

Airbag
Seven (7) airbags are installed in the Sorento PHEV, located in the areas shown in the image below. Before performing any emergency procedure, make sure the vehicle ignition switch is turned off and disconnect the negative connector from the 12V auxiliary battery (located in the left side motor compartment) to prevent accidental deployment of undeployed airbags.

1. Passenger front airbag
2. Driver front airbag
3. Side airbag (x2)
4. Curtain airbag (x2)
5. Driver’s centre airbag
   
   ❈ The actual airbags and seats in the vehicle may differ from the illustration.

Seat Belt Pretensioner
In the Sorento PHEV, the driver’s, front passenger’s and rear seat belts are equipped with pretenstioners. When the seat belt pretensioners are activated in a collision, a loud noise may be heard and fine dust, which may appear to be smoke, may be visible in the passenger compartment. These are normal operating conditions and are not hazardous. The seat belt pretensioner assembly mechanisms may become hot during activation and may need several minutes to cool down after they have been activated.

Seat Belt System

Undeployed Airbags

To avoid injuries caused by accidental deployment of undeployed airbags

• Do not cut the red-coloured part shown in the image above.
  

• Make sure the vehicle ignition switch is turned off, disconnect the negative cable from the 12V auxiliary battery (located in the left side of motor room) and wait 3 minutes or longer to allow the system to deactivate.
  

Failure to follow any of these instructions may result in serious injury or death from accidental deployment of the airbag system.

Documents / Resources

| ECO plug in 2022 MQ4 Sorento PHEV [pdf] User Guide
2022 MQ4 Sorento PHEV, 2022, MQ4 Sorento PHEV, Sorento PHEV, PHEV
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