19-01-036H

GROUP
Campaign
DATE
Technical Service Bulletin
SUBJECT
:
November,
2019
NUMBER
19-01-036H
MODEL(S)
Ioniq (AE)
HEV/PHEV/EV,
Kona (OS) EV
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT
- (CAMPAIGN T4G)
*** Dealer Stock and Retail Vehicles ***
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America's "Warranty
Vehicle Information" screen via WEBDCS to identify open Campaigns.
Description:
Certain vehicles may incur dash warning light(s) On with DTC(s) stored including either of the
following DTC:


U1116 - Lost Communication With Motor Electronics Coolant Pump (C-CAN)
U1118 - Lost Communication With Hybrid/EV Battery Electronic Coolant Pump (P-CAN)
The vehicle may operate in limp home at a reduced power.
The above DTC(s) may occur due to coolant leaking into the Electric Water Pump (EWP) Can Case
and may have an intermittent electrical connection.
This bulletin provides instructions to inspect the vehicle’s EWP assembly. The Can Case of the EWP
or the full EWP Assembly will be replaced depending on the EWP inspection result. The EWP’s
connector may also need to be replaced with a wiring harness kit if contamination is confirmed.
Perform the inspection procedure as outlined on page-7.

1 qty. EWP will be inspected in Ioniq HEV/PHEV/EV vehicles.

2 qty. EWP will be inspected in the Kona Electric (Electrical devices EWP and Battery EWP).
Applicable Vehicles:
 2019 Ioniq Hybrid (AE HEV)
 2019 Ioniq Plug In Hybrid (AE PHEV)
 2019 Ioniq Electric Vehicle (AE EV)
 2019 Kona Electric Vehicle (OS EV)
.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
Parts Information:
NOTE: *Actual quantity of each part depends on section-C (page-7) EWP inspection result.
Can Case Parts:
(Applicable when no coolant contamination is found by the section-C EWP inspection)
MODEL
Ioniq (AE)
Hybrid/
Plug-In
Ioniq (AE)
Electric
Kona (OS)
Electric
PART NUMBER
DESCRIPTION
QUANTITY
CAN CASE KIT
1 per
vehicle*
36900-2B109QQH
PICTURE
36910-0E509QQH
36910-0E659QQH
CAN CASE KIT
OS EV
up to 2 per
vehicle*
EWP Assembly Parts:
(Applicable when coolant contamination is confirmed by the section-C EWP inspection).
MODEL
Ioniq (AE)
Hybrid/
Plug-In
Ioniq (AE)
Electric
PART NUMBER
36900-2B100QQH
QUANTITY
PICTURE
1 per
vehicle*
36910-0E500QQH
Electrical Devices EWP:
Kona (OS)
Electric
DESCRIPTION
EWP ASSY
36910-0E650QQH
1 of each
type
per vehicle*
Battery EWP:
375W5-K4000QQH
EWP Wiring Harness Part:
(Applicable when coolant contamination is confirmed inside the EWP connection).
MODEL
PART NUMBER
DESCRIPTION
QUANTITY
PICTURE
Ioniq (AE)
1 per vehicle*
All Models
36910-G2912QQH
WIRING
HARNESS
-EWP
TSB #: 19-01-036H
Kona (OS)
Electric up to 2
per vehicle*
Page 2 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
Warranty Information:
MODEL
OP CODE
OPERATION
OP
TIME
CAUSAL
P/N
Ioniq (AE)
Hybrid/
Plug-In/
Electric
90C030R0
EWP INSPECTION AND EWP
REPLACEMENT
1.4
369002B100QQH
90C030R1
EWP INSPECTION AND CAN CASE
REPLACEMENT
1.0
369002B109QQH
90C030R2
EWP INSPECTION, ELECTRICAL
EWP + BATTERY CAN CASE
REPLACEMENT
1.8
369100E650QQH
90C030R3
EWP INSPECTION, BATTERY EWP +
ELECTRICAL CAN CASE
REPLACEMENT
1.8
375W5K4000QQH
90C030R4
EWP INSPECTION, ELECTRICAL &
BATTERY EWP REPLACEMENT
2.0
369100E650QQH
90C030R5
EWP INSPECTION, ELECTRICAL &
BATTERY CAN CASE
REPLACEMENT
1.5
369100E650QQH
Kona (OS)
Electric
NATURE CAUSE
CODE
CODE
I3A
ZZ7
NOTE 1: Submit claim on Campaign Claim Entry Screen.
NOTE 2: Coolant will be reimbursed under sublet for all op codes.
NOTE 3: If a part is found in need of replacement while performing this Service Campaign and the
affected part is still under warranty, submit a separate claim using the same Repair Order Number
and the same Causal Part Number as the Campaign Claim. If the affected part is out of warranty,
submit a Prior Approval Request for goodwill consideration prior to performing the work.
Cross Reference Chart of Op Codes versus Parts Replaced:
NOTE: Op Codes and Parts Replaced depend on section C (page-7) inspection results.
MODEL
OP CODE
CAN CASE KIT
EWP ASSY
*WIRING HARNESS
Ioniq (AE)
Hybrid/
Plug-In/
Electric
90C030R0
none
36900-2B100QQH
*36910-G2912QQH
90C030R1
36900-2B109QQH
none
none
36910-0E650QQH
(Electrical Devices EWP Assy)
*36910-G2912QQH
375W5-K4000QQH
(Battery EWP Assy)
*36910-G2912QQH
*Up to 2 qty.
36910-G2912QQH
none
90C030R2
90C030R3
Kona (OS)
Electric
36910-0E659QQH
(Can Case replaced in
the Battery EWP)
36910-0E659QQH
(Can Case replaced in the
Electrical Devices EWP)
90C030R4
none
36910-0E650QQH
(Electrical Devices EWP Assy)
+
375W5-K4000QQH
(Battery EWP Assy)
90C030R5
2 qty.
36910-0E659QQH
none
*Wiring harness is only replaced when coolant contamination is confirmed in the EWP connection.
TSB #: 19-01-036H
Page 3 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
Service Procedure:
DANGER
Review and follow the sections listed below from the applicable vehicle shop manual prior to
performing any work with the high voltage system:
 General Safety Information and Caution
 High Voltage Shut-Off Procedures
Failure to follow safety instructions may result in serious electrical injury.
Summary of the Repair Procedure:
Table of Contents:
Section
A
B
C
D
E
F
G
Content
Initial Vehicle Inspection
EWP Removal and Disassemble
EWP Inspection for Contamination
EWP Can Case Replacement
EWP Assembly Replacement
Harness EWP Connector Replacement
Coolant Fill and Bleed
TSB #: 19-01-036H
Page
5
5
7
8
9
10
11
Page 4 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
(A) Initial Vehicle Inspection:
1. Note if any cluster warning lights are ON
when vehicle is operating in Ready mode.
NOTICE
If any of these DTC are found stored:


2. If warning light is confirmed perform all
Fault search by GDS to check for any
stored DTC.
U1116
U1118
Skip to (section-E-F) (page-9) to replace the
EWP assembly and replace connector.
(B) EWP Removal and Disassemble:
1. Carefully remove each EWP from the
vehicle according to the applicable shop
manual instructions.
NOTICE


OS EV has 2 EWP to be removed
(Electrical Devices & Battery EWP).
Clamp the coolant hoses from the
High Voltage Battery to reduce
coolant fill and GDS bleeding time
that will be needed in section-G.
2. Inspect the inside of both connectors of
the EWP connection for coolant
contamination:
 No contamination is found:
Continue to next step 3.
 Contamination is found:
Skip to (section-E) (page-9) to
replace the EWP assembly and
(section-F) (page-10) vehicle
harness EWP connector.
EWP part side
Wire Harness Connector
3. Remove the EWP Pump Cover mounting
bolts.
TSB #: 19-01-036H
Page 5 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
4. Remove the Pump Cover and O-ring.
5. Remove the Can Case from the housing.
Can Case
Stator
6. Remove the Stator O-ring.
TSB #: 19-01-036H
Page 6 of 11
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
SUBJECT:
(C) EWP Inspection for Coolant Contamination:
Inspect for evidence of any coolant leak or
contamination stains found on the inside
of any of the following EWP components:
 Can Case (on the side facing the stator):
 Stator:
 Connector:
NOTICE
The vehicle harness connector must be
replaced (section-F) (page-10) if
contamination is found inside connector.
NOTE: If no contamination was found in any
of the above 3 components proceed to the
next page-8 to replace the Can Case only.
TSB #: 19-01-036H
Page 7 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
(D) Can Case Replacement:
(No Coolant contamination was found inside the EWP)
1. Replace the CAN Case using the new
part specified in the Parts Information
table when both conditions of a-b were
found:
a. No cluster warning light.
b. No coolant contamination was
found during the EWP inspection.
NOTICE
The Stator O-Ring is identified by the
white marking.
CAUTION
Prevent any interference between the
O-ring and the pump cover as shown.
2. Reinstall EWP disassembled parts in
reverse order of removal.
3. Reinstall the EWP back on the vehicle.
4. Go to section (G) (page-11) – Fill and
Bleed the Hybrid/Plug-In/EV system
coolant.
TSB #: 19-01-036H
Page 8 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
(E) EWP Assembly Replacement:
(Coolant contamination was found inside the EWP)
1. Replace the EWP Assembly with the
new part from the Parts Information
table.
2. Locate the EWP wiring connector on the
vehicle harness.
NOTE: As needed, separate the connector
mounting clip before replacing the EWP
connector.
TSB #: 19-01-036H
Page 9 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
(F) Harness EWP Connector Replacement:
(Coolant contamination was found inside the EWP connection)
1. Carefully remove the vehicle harness
wiring tape back from the EWP
connector using the cutter tool.
2. Cut all wires before the harness EWP
connector to remove the old connector.
Discard the old connector.
3. Strip back the insulation ½ inch from the
end of each of the 4 harness wires to
expose the wire.
4. Obtain the EWP replacement connector
kit as listed in the Parts Information
table.
5. Place a heat shrink tube loosely over
each wire against the connector prior to
joining each wire.
Step-5
Step-6
6. Join together and solder evenly each
matching colored pair of wires between
the vehicle harness and the replacement
EWP connector.
CAUTION
Keep the connector kit’s red and green
signal wire pair twisted together as this
prevents electrical noise on the vehicle
CAN system that can cause other issues!
TSB #: 19-01-036H
Page 10 of 11
SUBJECT:
SUBJECT:
ELECTRIC WATER PUMP (EWP) CAN CASE REPLACEMENT – (CAMPAIGN T4G)
7. Move each heat shrink tube to fully cover
each wire joint with the joint centered in
the tube.
8. Apply heat to each heat shrink tube to
contract it to create a good water tight
seal.
9. Wrap the repaired harness fully using the
harness tape provided in the EWP
connector kit.
(G) Coolant Fill and Bleed:
1. Perform the Hybrid/Plug-In/EV system
coolant fill and bleed procedure following
the guidelines in the shop manual.
NOTICE
If available connect a battery charger to
the 12V battery to maintain battery state
of charge while the EWP is running, as it
takes at least 20-30 minutes continuously
to bleed the coolant.
2. Scan and Clear any incidental DTCs with
the GDS.
3. Confirm proper vehicle operation.
4. Rescan for DTCs to ensure that none
have returned.
Service procedure is complete.
TSB #: 19-01-036H
Page 11 of 11
SUBJECT: