19-EE-003H

GROUP
ENGINE
ELECTRICAL
DATE
Technical Service Bulletin
SUBJECT:
NUMBER
19-EE-003H
MODEL
Sonata Hybrid
(YF HEV/LF HEV),
APRIL, 2019 Sonata Plug-In (LF PHEV),
Ioniq Hybrid/Plug-In
(AE HEV/PHEV), Nexo (FE)
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
Description:
The following summarizes the service procedures for Lithium Battery replacement:
IMPORTANT
Do not disconnect or remove the 12V or High Voltage battery before the Battery
Management System (BMS) DTC Analysis and Data Analysis screens are collected by GDS.
Section
A.
B.
C.
D.
E.
F.
Content
Dealer uses GDS to collect the following:
 BMS DTC Analysis.
 BMS Data Analysis.
 Dealer calls Techline to open a case.
 Dealer sends BMS Data Analysis capture file(s) to Techline repository or
email.
If it qualifies, Techline approves Dealer’s Lithium Battery replacement, and a
Lithium Battery is shipped to the Dealer. Techline will call back with
confirmation of the shipment estimated time of arrival.
Once the replacement battery is on hand, dealer removes and replaces the
battery.
 After replacement confirm the vehicle can go into Ready mode without
warning lights on.
 (For YF HEV only: Perform BMS Update per TSB 18-HC-003).
 Clear DTC by GDS and make sure no battery related DTC return.
 Perform SOC Calibration by GDS within the BMS software management.
 Secure the removed used Lithium Battery core in the shipping box from
the replacement battery.
 Dealer Parts Dept. requests battery return by KBI of the used battery core
per TSB 19-EE-001.
Applicable Vehicles:






Pages
3-4
5
5
6
6
7
2011-2015MY Sonata Hybrid (YF HEV)
2016MY~ Sonata Hybrid (LF HEV)
2016MY~ Sonata Plug-In Hybrid (LF PHEV)
2017MY~ Ioniq Hybrid (AE HEV)
(High Voltage Battery and 12V Battery)
2017MY~ Ioniq Plug-In Hybrid (AE PHEV)
2019MY Nexo (FE) (High Voltage Battery and 12V Battery)
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT:
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
Warranty Information:
Model
Op Code
Operation
37510R1H
BATTERY PACK ASSY
(MAIN HIGH VOLTAGE
BATTERY)
Sonata Hybrid
(YF HEV)
37510RQ0
37510R2H
Sonata Hybrid
(LF HEV)
37510RQ0
Sonata Plug-In
Hybrid
(LF PHEV)
Ioniq Hybrid
(AE HEV)
High Voltage
Battery
37510R2H
37510RA1
PLUG IN HEV (MAIN)
37510RQ0
DIAGNOSTIC TOOL
OPERATION
HIGH VOLTAGE BATTERY
PACK ASSY
37510RQ0
37513R00
Ioniq Hybrid
(AE HEV)
12V Battery
37503RQ0
37510R00
Nexo (FE)
High Voltage
Battery
Cause
Code
I3A
ZZ3
37510-*****
37503-*****
Refer to
WebLTS
for current
LTS Time
37501-*****
DIAGNOSTIC TOOL
OPERATION
HIGH VOLTAGE
BATTERY SYSTEM ASSY
(PHEV)
37503-*****
DIAGNOSTIC TOOL
OPERATION
HIGH VOLTAGE BATTERY
PACK ASSY
37510-*****
37510RQ0
37513R00
Nexo (FE)
12V Battery
Nature
Code
37507-*****
37513RQ0
37503R1H
Ioniq Plug-In
Hybrid
(AE PHEV)
DIAGNOSTIC TOOL
OPERATION
BATTERY MANAGEMENT
SYSTEM BMS
Causal
Part
37511-*****
DIAGNOSTIC TOOL
OPERATION
BATTERY PACK ASSY
(MAIN HIGH VOLTAGE
BATTERY)
DIAGNOSTIC TOOL
OPERATION
BATTERY PACK ASSY
(MAIN HIGH VOLTAGE
BATTERY)
37510R00
Op Time
DIAGNOSTIC TOOL
OPERATION
BATTERY MANAGEMENT
SYSTEM BMS
37507-*****
37513RQ0
DIAGNOSTIC TOOL
OPERATION
*****Refer to the part number of the battery ordered for the vehicle or the Parts
Catalog for the full part number to be entered in the claim for Causal Part.
TSB #: 19-EE-003H
Page 2 of 6
SUBJECT:
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
Service Procedure:
A-1. Perform the GDS All Fault Search function to review all stored DTC(s).
BMS DTC Search Result:
 Review for any BMS system DTC stored. Verify in the shop manual if any have a
possible cause of Lithium Battery.
 If BMS DTC does not apply to a potential battery problem, this TSB doesn’t apply.
A-2. Capture all data from the GDS BMS Data Analysis function as follows:
(Preferred) GDS has an SD card:
GDS does not have an SD card:

Capture first page of Data Analysis by either:
 Manual tablet screenshot (press LOCK and
HOME buttons together).
 Camera shot (with flash off).
Use the GDS Data Capture function that can
be found by scrolling to the right at the top of
the GDS screen:



Selecting the Save button creates a PDF file of
the multiple pages of all the data of the Data
Analysis.

TSB #: 19-EE-003H
Note the parameter at the bottom of the screen
and manually scroll down until that parameter
shows at the top of the screen.
Capture a manual tablet screenshot or camera
shot of the 2nd page of data.
Continue the above steps page by page until all
Data Analysis pages are captured & saved.
Page 3 of 6
SUBJECT:
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
B-1. Contact Techline at 1-800-325-6604 to open a Techline Case to request approval of a Lithium
Battery replacement. Note the Techline case number assigned.
B-2. Upload the following to the Techline Repository or email to: [email protected]:
 BMS Data Analysis Data Capture file(s).
NOTE: Be sure to include Dealer Number, VIN and Techline Case# in the subject line of
each Techline Repository or email submission, so Techline can match to your case.
General Instructions on how to Upload to Techline Repository are found at Technical Training –
Techline Procedures:
C.
Once Techline approval is received, the Lithium Battery will be shipped out to the Dealer.
Shipping can take 2-5 days depending on location since the Lithium Battery can only be
shipped by Hazmat ground transportation.
Dealer will be contacted by Techline to confirm whether the battery was shipped and provide an
estimated time of arrival (ETA).
TSB #: 19-EE-003H
Page 4 of 6
SUBJECT:
D.
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
After the Lithium Battery is on hand at Dealer, remove the battery from the vehicle per the
specific shop manual instructions for each model.
Begin by removing the service plug from the battery and wait 5+ minutes for inverter discharge.
Shop Manual Example - Ioniq HEV: High Voltage Battery System – Repair Procedures:
E-1. After installation is complete, check that the
vehicle will go into READY mode and there are
no warning lights on.
E-2. For 2011-2015 Sonata Hybrid (YF HEV) battery replacement only:
Perform BMS Update per TSB 18-HC-003.
TSB #: 19-EE-003H
Page 5 of 6
SUBJECT:
HYBRID/PLUG-IN/FUEL CELL LITHIUM BATTERY REPLACEMENT PROCEDURES
E-3. Check All Fault Search DTC and clear DTC.
Make sure no BMS battery related DTC
returns.
See an example of a screen with no DTC,
confirming that proper battery installation had
occurred.
E-4. Perform the SOC Calibration found in the S/W
Management , High Voltage Battery System
section of GDS.
F.
Place the original used Lithium Battery core in
the shipping box in a similar manner as was
received for the replacement battery.
Dealer Parts Dept. must follow TSB 19-EE-001
to schedule pickup by KBI of the used battery
core as soon as possible. KBI will provide
specific instructions.
TSB #: 19-EE-003H
Page 6 of 6