19-EE-002H

GROUP
ENGINE
ELECTRICAL
Technical Service Bulletin
SUBJECT:
DATE
APRIL, 2019
NUMBER
19-EE-002H
MODEL
Kona Electric (OS EV)
Ioniq Electric (AE EV)
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT PROCEDURES
IMPORTANT

Carefully follow all steps of this TSB. The required special tools and TSB procedures
are very important for safe handling of a large heavy EV battery.

Do not disconnect or remove the 12V or EV battery before the Battery Management
System (BMS) DTC Analysis and Data Analysis screens are collected by the GDS.

The removed EV battery must be carefully handled to avoid physical damage per the
procedures of this TSB.
Description: The following summarizes the service procedure for EV battery replacement:
Section
Content
Pages
A.
Dealer uses GDS to collect BMS DTC Analysis and BMS Data Analysis.
3-4
Dealer calls Techline to establish a Techline Case.
B.
5
Dealer sends the BMS Data Analysis screen capture file(s) to Techline
repository or by email to request an EV battery replacement approval.
C.
Techline approves Dealer EV battery replacement and an EV battery will be
5
shipped to Dealer. Techline will call back to confirm estimated time of arrival.
D.
Required Tools will be shipped as “essential” to Dealer from Bosch and billed
2, 5
one time to Dealer.
E.
Dealer Technician performs the required online EV Battery Replacement
5
Training Module. Technician will receive training credit.
F.
Once the required tools and the replacement EV battery are on hand,
6-11
Dealer removes and replaces the EV battery.
G.
Confirm the vehicle can go into Ready mode without warning lights on.
11
Clear DTC by GDS and make sure no battery related DTC were restored.
Perform SOC Calibration by GDS.
H.
Kona Only: Fill the P/E coolant reservoir and bleed by GDS for 30 minutes.
12
I.
Dealer test drives the vehicle.
13
Check that it takes a level-1 or level-2 charge.
J.
Secure the removed battery to the shipping box from the replacement battery.
13
For Kona only make sure the battery coolant nipples are plugged.
Install the battery box cover securely.
K.
Dealer Parts Dept. requests battery return by KBI of the used battery core per
13
TSB 19-EE-001.
Applicable Vehicles:


2017-2019MY Ioniq Electric (AE EV)
2019MY~ Kona Electric (OS EV)
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
Warranty Information:
Model
Op Code
Operation
37510R00
HIGH VOLTAGE BATTERY
PACK ASSY
Kona Electric
(OS EV)
37510RQ0
DIAGNOSTIC TOOL
OPERATION
37503R00
HIGH VOLTAGE
BATTERY SYSTEM ASSY
Ioniq Electric
(AE EV)
37510RQ0
DIAGNOSTIC TOOL
OPERATION
Op Time
Causal
Part
Nature
Code
Cause
Code
Refer to
WebLTS
37501K4000
I3A
ZZ3
Refer to
WebLTS
37501G7200
I3A
ZZ3
EV Battery Required Special Tools Information:

The following special tools are required for the safe, secure, efficient lifting of large heavy EV
battery (~1000lbs). Proper tools are required to avoid damage to the EV battery.

Both tools will be shipped from Bosch to any Dealer at their first EV battery replacement
service as a required special tool.
PART NAME /
(Part Number)
DIAGRAM
REMARK
Shipped from Bosch
Propulsion System
Lift Table
Allows for safe and efficient EV
battery replacement.
(P/N: HMA52200-A)
Engine hoist can fit under it to
raise an EV battery from the table.
Multi-Use air/hydraulic operated
lift rated at 1760 lbs capacity can
lift 21.5 to 70 inches high.
Multiple uses include EV Battery,
Engine/Transaxle, Fuel Tank,
Cradles, Suspensions, and
Chassis systems.
High Voltage Battery
Lifting Fixture
Shipped from Bosch
(P/N: 09375-K4100)
TSB #: 19-EE-002H
Page 2 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE 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 EV battery.
 If BMS DTC does not apply to a potential EV battery problem, this TSB does not 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:
Use the GDS Data Capture function that can be
Capture the first page of Data Analysis, either by:
found by scrolling to the right at the top of the GDS  Manual tablet screenshot (press LOCK and
screen:
HOME buttons together).
 Camera shot (turn off flash).


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.
Selecting the Save button creates a PDF file of the
multiple pages of all the data of the BMS Data
Analysis.

TSB #: 19-EE-002H
Continue the above steps page by page until all
Data Analysis pages are captured & saved.
Page 3 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
B-1. Contact Techline at 1-800-325-6604 to open a Techline Case for approval of an EV 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 EV Battery will be shipped out by Mobis to the Dealer.
Shipping can take 2-5 days depending on location since EV battery can only be shipped by
Hazmat ground transportation. Techline will confirm the estimated time of arrival (ETA).
D.
Required Tools on page-2 will ship out from Bosch (if not already been sent out).
E.
Perform the EV Battery Replacement Online Training Module on the “Hyundai Technical
Training” Learning Portal (if a Hyundai only Dealer) or, on the “Learning Portal” (if a dual
Hyundai and Genesis Dealer). The course will provide Technician training credit.
Hyundai Dealer:
TSB #: 19-EE-002H
Dual Hyundai and Genesis Dealer:
Page 4 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
F-1. After the EV battery and special tools are on hand, remove the EV battery from the vehicle per
the specific shop manual instructions for each model and place the battery on the lift table.
Begin by removing the service plug from the battery and wait 5+ minutes for inverter discharge.
Refer to the Battery Removal Tips on the next page.
Kona EV: High Voltage Battery System – Repair Procedures:
Ioniq EV: High Voltage Battery System – Repair Procedures:
TSB #: 19-EE-002H
Page 5 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
F-2. Battery Removal Tips:

You must use the SST P/N: HMA52200-A
Propulsion System Lift Table as shown in
the Required Tools section.
Place a piece of cardboard on the table top
of 1/8 inch thickness minimum.
Kona EV Only:

When disconnecting the coolant hoses from
the Kona EV battery, clamp the hoses
carefully from the vehicle side to avoid
losing coolant from the reservoir.

Catch the coolant that drains and discard it.

Attach a short spare coolant hose (from
your shop supply) to one side of the pair of
coolant nipples from the battery.
Blow out all the coolant from the battery
from the other coolant nipple using shop air
as shown.

Loop and attach the spare coolant hose to
both coolant nipples from the battery.
NOTE: Clamp the hose at both nipples to
prevent coolant from draining during
handling and shipping of the battery.
TSB #: 19-EE-002H
Page 6 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
F-3. Exchanging Battery from the Vehicle with the Service Battery:
a)
When the EV battery is received in the shipping box use a fork lift (with extenders if available)
or pallet jack to carefully lift and transport the battery to the work site.
NOTE: There are 2 different styles of boxes, each is opened in different ways:
OEM Box:

OEM EV battery box will have a top cover
that is secured by nails or screws.

Nails will need to be pried up or screws
removed to be able to remove the cover.
Refurbished EV Battery Box:

Refurbished EV battery box has a full cover
integrated with side panels.

It may include clips at the bottom that
secure the cover to the bottom crate that
holds the battery. These clips will need to
be removed and saved for attaching back.

Flip up the full cover assembly as shown.

Remove the straps securing the battery in
place.
TSB #: 19-EE-002H
Page 7 of 12
SUBJECT:
b)
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
Assemble the High Voltage Battery Lifting
Fixture SST P/N: 09375-K4100 to the EV
battery as per the instructions provided with
the kit depending on model and type of battery.
NOTE: For Kona EV battery, use the (OS EV
PACK Extended Type) instructions. Do not
follow instructions for the Economical Pack.
The following instructions depend on whether a Fork Lift (preferred) or an Engine Hoist is used:
Fork Lift Instructions:
Engine Hoist Instructions:
c)
Use a fork lift with chains and the Lifting
Use a pallet jack on one side to raise the crate
Fixture Kit to raise up the replacement battery: to make it possible to fit an Engine Hoist in
place on the other side to lift up the battery.
d)
Move the replacement EV battery and carefully
place it on the shop floor as a temporary
resting point.
Remove the Lifting Fixture Kit from the battery.
TSB #: 19-EE-002H
Move the replacement battery with the Engine
Hoist to a spare shop lift or other suitable
raised surface that would allow for the Engine
Hoist to roll under to receive the battery. This
will be a temporary resting point.
Remove the Lifting Fixture Kit from the battery.
Page 8 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
Fork Lift Instructions:
Engine Hoist Instructions:
e)
After the EV battery was removed from the
vehicle, install the Lifting Fixture Kit to be able
to raise it from the Lift Table by Fork Lift.
After the EV battery was removed from the
vehicle, install the Lifting Fixture Kit to be able
to raise it from the Lift Table by Engine Hoist.
f)
Move the EV battery from the vehicle to the
Move the EV battery from the vehicle to the
shipping crate and carefully lower it in place so shipping crate and carefully lower it in place so
it is centered on the crate.
it is centered on the crate.
g)
Transfer the Lifting Fixture Kit back to install on
the replacement battery.
Raise the replacement battery from its
temporary resting point and place it onto the
Lift Table.
TSB #: 19-EE-002H
Transfer the Lifting Fixture Kit back to install on
the replacement battery.
Raise the replacement battery from its
temporary resting point (of step-d) and place it
onto the Lift Table.
Page 9 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
F-3. Install the replacement battery to the vehicle in
reverse of the shop manual removal
instructions.
G-1. After installation is complete, check that the
vehicle will go into READY mode and there are
no warning lights on.
NOTE: (For Kona only). The Powertrain
Electronics (P/E) coolant has not been filled
yet, so a low cooling warning light might occur,
but that will be taken care of at step H.
G-2. Check All Fault Search DTC and clear DTC.
Make sure no BMS battery related DTC
restores.
See example of a BMS screen with no DTC,
confirming that proper battery installation had
occurred.
G-3. Perform the SOC Calibration found in the S/W
Management , EV Battery System section of
GDS.
TSB #: 19-EE-002H
Page 10 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
(Step H applies to Kona EV Only):
H-1. Fill the P/E cooling system reservoir to the
MAX full mark with 50/50 mixture of coolant
and water.
H-2. Using GDS with Ignition ON, perform the P/E
cooling system air bleeding procedure.
This will take about 30 minutes.
As the air is purged, recheck and add coolant
as necessary.
TSB #: 19-EE-002H
Page 11 of 12
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
I-1. Perform a test drive for at least 2-3 miles and
make sure vehicle is OK.
I-2. Confirm the battery will take charge from a
Level-2 charger (faster) or the Level-1 charger
that came with the vehicle.
Recommended to keep the vehicle on a Level2 charger until customer picks up the vehicle,
so it can be delivered at the highest possible
charge.
J-1. Secure the used EV battery tightly in place with
the provided straps onto the crate to minimize
any movement during shipping.
J-2. For Kona EV only, ensure there will be no
coolant leaking out of the battery onto the
shipping crate.
Use a spare coolant hose from your shop to
loop and clamp over the 2 coolant nipples.
J-3. Place the cover on the battery shipping box
and make sure it is firmly in place to prevent
the cover from dislodging during the return
shipping. Secure any clips if they came with
the box originally.
K.
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-002H
Page 12 of 12