5NP-X4Q7Y-01

GROUP
NUMBER
17-HC-004
HYBRID CONTROL
DATE
Technical Service Bulletin
SUBJECT:
MODEL
DECEMBER, 2017
SONATA PLUG IN
HYBRID
(LF PHEV)
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
NOTICE

Carefully follow all Service Procedure steps and NOTICES to ensure high voltage
safety and correct repair.

Print this TSB in color for adequate contrast to accurately identify all pertinent
components, harness, connectors, and bolt/nut locations of the service procedure.
Description:
Some 2016-2017MY SONATA PLUG IN HYBRID (LF PHEV) vehicles may develop a Check Hybrid
System Light On with the following DTC found stored in the Battery Management System (BMS):
 DTC P1BA7 - Overcharge Detection Active
In addition, one or both of the following DTCs may also be stored along with the DTC P1BA7:
 DTC P1B77 - High Voltage Battery Precharging Fault
 DTC P1B25 - Hybrid Battery Safety Plug Or Fuse Circuit
NOTE: This bulletin does not apply for just a DTC P1B77 or P1B25, it must also have P1BA7.
This bulletin’s Service Procedure will convert the PHEV battery overcharge detection system from a
Voltage Protection Device (VPD) mechanical type switch to an Overvoltage Protection Device (OPD)
electronic type device internal to both the new SUB BMS and MAIN BMS.
The following will be performed to achieve the conversion to an OPD type system:
 Replace the Sub and Main BMS.
 Replace Sub and Main BMS Wiring.
 Perform OBC ECU Software Update.
Applicable Vehicles:
Certain 2016-2017MY Sonata Plug-In Hybrid (LF PHEV) vehicles
produced between Jun 24, 2015 to Aug 31, 2017.
Warranty Information:
Model
Op Code
Operation
Op Time
Causal
Part
Nature
Code
Cause
Code
Sonata
Plug-In Hybrid
(LF PHEV)
37513F01
BMS & WIRING
REPLACEMENT AND
OBC UPGRADE
2.3 M/H
37503E6AS1
I3A
ZZ3
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
Parts Information:
PART NAME
FIGURE / PART NUMBER
MAIN BMS
REMARK
1 per vehicle
37513-E6520
SUB BMS
1 per vehicle
37513-E6620
MAIN BMS WIRING
1 per vehicle
37517-E6520
SUB BMS WIRING
1 per vehicle
37517-E6620
Required Tools List:

Safety Gloves

Cordless impact gun 3/8”

Cordless screw gun

Ratchet 3/8”

Torque wrench

10mm 3/8” socket

12mm 3/8” socket

17mm 3/8” socket

Small and Medium 3/8” Extensions

Trim tool remover

Electrical tape

Pocket flat head
TSB #: 17-HC-004
Page 2 of 16
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
Service Procedure:
1.
Per HEV “General Safety Information and
Caution”, wear insulated safety gloves for
this entire service procedure.
a
Unfasten the hook (a) and remove the safety
plug (b) by pulling the lever (c) in the direction
of the arrow.
b
c
! WARNING
Be sure to read and follow the
“General Safety Information and
Caution” before doing any work
related with the high voltage
system.
Wait 5 minutes after disconnection
to allow for high voltage system
capacitor discharge.
Failure to follow the safety
guidelines may result in serious
electrical injuries.
Vehicle Safety Related Disconnects:


The negative terminal to the 12V auxiliary
battery should be removed.
(NOTE: Record customer radio presets to
be able to restore them after service.)
12V Battery
Negative
Terminal
High Voltage Battery
Safety Plug
High voltage battery safety plug according
to the above procedure.
NOTICE
There is only one safety plug
disconnection to safely disconnect
both the PHEV Main and Sub High
Voltage Battery.
TSB #: 17-HC-004
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SUBJECT:
2.
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
Remove the following to be able to access
both PHEV Main and Sub High Voltage
Battery:





Rear Seat Lower Assembly.
Rear Seat Back Assembly.
Trunk Partition Board.
Trunk Cover Board and Felt.
Trunk Felt Side Trims on both sides.
Refer to the Service Manual for detailed
removal instructions.
This diagram identifies both the Main and Sub
High Voltage Battery Packs in the PHEV 
Main
n
Sub
3.
Disconnect the BMS and high voltage
connectors (A) from the Sub High Voltage
Battery.
4.
Remove the mounting nuts and cooling duct
(B) from the Sub High Voltage Battery.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
5.
Remove the mounting bolts and Sub High
Voltage Battery Pack from the vehicle.
Tool: 17mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
78.4 ~ 117.7N.m (8.0 ~ 12.0 kgf.m,57.9 ~ 86.8lb-ft)
6.
Remove the mounting bolts and aluminum
cover from the Sub High Voltage Battery Pack.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Remove the dark water tight cover from the
Sub High Voltage Battery Pack.
7.
Disconnect the BMS connectors and remove
the Sub-BMS.
NOTICE
The old Sub-BMS ECU will be discarded
and replaced later at step-14 by the new
SUB BMS P/N 37513-E6620.
TSB #: 17-HC-004
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SUBJECT:
8.
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
Loosen the ground bolt socket and mounting
clips.
Pull out the wiring as shown in the picture to
the right.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
9.
Place the Sub High Voltage Battery Pack
upside down.
Remove the mounting bolts and the watertight
case (C).
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Cover removed
10. Remove the VPD mounting bolts and discard
(NOTE: VPD will be discarded with the wiring).
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
11. Remove the wiring mounting clips and
disconnect the connector.
Tool: Trim tool remover and pocket flat head.
12. Remove the mounting clips and remove the
VPD mounting bolts.
13. Remove and discard the existing Sub-BMS
Wiring including VPD and its 2 mounting bolts.
14. Install the new SUB BMS WIRING
P/N 37517-E6620.
NOTICE
The new SUB BMS WIRING does not
have a VPD, it is no longer needed.
15. Reinstall the watertight cover to the Sub High
Voltage Battery Pack.
Turn the battery pack back over on the cover
side.
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
15. Install the new SUB BMS P/N 37513-E6620.
NOTICE
Make sure to connect all BMS
connectors are fully secured into place
until a clicking sound is heard.
16. Reinstall the removed parts on the Sub High
Voltage Battery Pack in reverse order of
removal.
NOTE: The Main High Voltage Battery Pack
will not be removed from the vehicle.
17. Loosen the mounting bolts and remove the
front cover (D) of the Main High Voltage
Battery Pack.
18. Disconnect the BMS connector.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
19. Loosen the mounting bolts and remove the
rear cover (E) of the Main High Voltage Battery
Pack.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
20. Loosen the mounting bolts, nuts, and remove
the cover (F) of the Main High Voltage Battery
Pack.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Ratchet 3/8”.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
21. Disconnect the OBC and CPU connectors.
Loosen the ground bolt.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
22. Remove the inverter power positive and
negative cable terminals.
!
WARNING
Be careful not to have the positive and
negative cable terminals make contact to
each other. Tape each terminal
temporarily with electrical tape to help
prevent contact between the terminals.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Ratchet 3/8”.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
TSB #: 17-HC-004
Page 9 of 16
SUBJECT:
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
23. Disconnect the fan connector.
24. Remove the cooling duct mounting bolts and
nuts.
Remove the harness retainers to the cooling
fan.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
25. Remove the mounting screws and cooling duct
(G).
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
26. Disconnect the cooling fan connectors and
mounting nuts to remove both cooling fans
(H & I).
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
27. Disconnect the BMS connectors (J).
28. Remove the mounting nuts and the Main BMS
(K).
NOTICE
The old Main BMS will be discarded and
replaced later at step-37 by the new
MAIN BMS P/N 37513-E6520.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
TSB #: 17-HC-004
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SUBJECT:
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
29. Disconnect the Power Relay Assy. (PRA)
connectors.
30. Remove the mounting bolts and remove the
PRA (L).
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
View after PRA removed.
TSB #: 17-HC-004
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SUBJECT:
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
31. Remove the wiring mounting clips and ground
bolt.
Disconnect the connector.
Tool: 10mm 3/8” socket + cordless 3/8” impact
gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
32. Remove the main wiring harness mounting
clips.
Tool: Trim tool remover and pocket flat head.
TSB #: 17-HC-004
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
33. Remove the mounting clips, VPD nuts, and
ground bolt.
34. Remove and discard the existing Main BMS
Wiring, the VPD and its 2 mounting nuts.
NOTICE
The new MAIN BMS WIRING does not
have a VPD. They are no longer needed.
35. Install the new MAIN BMS WIRING P/N
37517-E6520.
36. Reinstall the PRA.
37. Install the new MAIN BMS P/N 37513-E6520.
NOTICE
Make sure to connect all BMS
connectors fully into place until a
clicking sound is heard.
38. Reinstall all the remaining removed parts in reverse order of removal.
39. Using GDS perform the OBC ECU Software Update Procedure (see the next 2 pages).
40. Perform a brief few minute test drive to ensure the vehicle is operating normally. If possible
confirm vehicle can take a charge indicating the green charge light on top center of the dash.
41. Perform Fault Code Search of All Systems by GDS to make sure there are no stored DTC.
42. Restore the recorded customer radio presets and set the time.
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DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
SUBJECT:
OBC ECU Software Update Procedure:
ROM ID Table:
MODEL
SYSTEM
OBC P/No.
LF PHEV
OBC
36400-3D025
ROM ID
OLD
NEW
5.01
5.03
5.05
Precautions for ECU Update:
 Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage an
extended time, operate the vehicle in ready mode for at least 20 minutes to assure an
adequate battery charge state for reliable upgrade results.
 Make sure GDS has at least 30% battery. Charge the GDS tool if needed.
 Turn off all vehicle interior lamps (do not leave head lamp switch in auto mode.) and all
vehicle accessories (including heater, A/C, blower, radio, seat warmer, defroster, etc.) so the
battery will not lose charge during upgrade.
 Perform GDS ECU Upgrade with the ignition switch left in the ON position.
 Do not start the engine during the ECU Upgrade.
Automatic Mode Upgrade Procedure:
A.
Select ECU Upgrade on the initial screen after
entering the vehicle information.
B.
Select Auto Mode and then select OBC for
System.
C.
Select ID Check.
D.
GDS will read Current ROM ID and confirm
that the upgrade applies to the vehicle.
E.
Select the upgrade event. Touch Upgrade.
“461.LF PHEV OBC - CHARGING LAMP
CONTROL LOGIC IMPROVEMENT”
TSB #: 17-HC-004
Page 15 of 16
SUBJECT:
DTC P1BA7 PHEV BATTERY BMS AND WIRING REPLACEMENT
F.
Vehicle 12V Battery Voltage is checked to
make sure it is at least 12.0 volts to assure
reliable upgrade results.
 Click OK if the result is Good >12V,
 “Low Battery Warning”:
Select Back button at top right corner:
o Operate vehicle in Ready mode
for 15 minutes and shutdown.
o Turn Ignition On and recheck.
G.
Upgrade (1/2) will begin and the progress will be displayed on bar graph until 100% is reached.
H.
Upgrade (2/2) will begin and the progress will be displayed on bar graph until 100% is reached.
I.
When prompted, Turn ignition key OFF for 10 seconds. Place it back to the ON position and
select OK to continue according to the information displayed on the GDS screen.
J.
Select OK on the final screen that indicates the Upgrade is complete.
K.
Select All Fault Search to scan all systems for DTC after the Upgrade, and then select Erase
all DTC.
Manual Mode Upgrade Procedure:
NOTICE


The Manual Upgrade should be performed only when the Automatic Upgrade
fails after a partial bar graph was displayed.
If Automatic Upgrade fails, turn the ignition key OFF for about 10 seconds, place it
back in the ON position to reset the control unit before performing Manual Upgrade.
a.
Within the ECU Upgrade screen, select
Manual Mode, then select the Upgrade Event
461.
b.
Select the appropriate ECU part number:
OBC 36400-3D025.
c.
Enter the Password as 3025.
NOTE: The remaining ECU Upgrade steps
are identical to those of steps F-K of the above
Auto Mode Procedure.
TSB #: 17-HC-004
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