20-EE-001H-2

GROUP
ENGINE
ELECTRICAL
Technical Service Bulletin
SUBJECT:
DATE
October, 2020
NUMBER
20-EE-001H-2
MODEL
Kona Electric (OS EV)
Ioniq Electric (AE EV)
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT PROCEDURES
(This TSB supersedes 20-EE-001H-1 to update the tool acknowledgment form and the
battery removal notes section)
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, as it will be returned for repair and future reuse.
Description: The following summarizes the procedure for EV battery replacement:
Section
Content
A.
Dealer uses GDS to collect BMS DTC Analysis and BMS Data Analysis.
B.
Dealer calls Techline to establish a case for EV battery replacement.
Both of the following must be sent to Techline Email or Repository:
 EV Battery Replacement Required Special Tools Acknowledgement form.
 BMS Data Analysis screen capture file(s).
C.
Techline approves EV battery replacement case and an EV battery will be
shipped to Dealer. Techline will call back to confirm arrival estimate (ETA).
D.
For first time EV Battery replacement cases, the EV Battery Special Tools will
be shipped to Dealer from Bosch and billed one time to Dealer.
E.
Dealer Technician performs the required online EV Battery Replacement
Training Module before battery arrives. Technician will receive training credit.
F.
Once the required special tools and the replacement EV battery are on hand,
Dealer can remove and replace the EV battery.
G.
 Confirm the vehicle can go into Ready mode without warning lights on.
 Clear DTC by GDS and make sure no battery related DTC restore.
 Perform SOC Calibration by GDS.
H.
Kona and 2020MY~ Ioniq: Fill the P/E coolant reservoir and bleed by GDS.
I.
Dealer test drives the vehicle. Check that it takes a level-1 or level-2 charge.
J.
 Secure removed battery to the shipping box from the replacement battery.
 Make sure the battery coolant inlet and outlet nipples are plugged.
 Install the battery box cover securely.
K.
Dealer Parts Dept. requests battery return by KBI per TSB 19-EE-001.
Applicable Vehicles:


Pages
5
6
6
6
6
7-12
12
13-14
15
15
15
Ioniq Electric (AE EV)
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
Kona Electric
(OS EV)
2017-2019MY
Ioniq Electric
(AE EV)
2020MY~
Ioniq Electric
(AE EV)
Op Code
37510R00
37510RQ0
37510R00
Operation
HIGH VOLTAGE BATTERY
PACK ASSY
DIAGNOSTIC TOOL
OPERATION
HIGH VOLTAGE BATTERY
PACK ASSY
37510RQ0
DIAGNOSTIC TOOL
OPERATION
37510R4H
HIGH VOLTAGE BATTERY
PACK ASSY
37510RQ0
DIAGNOSTIC TOOL
OPERATION
Op Time
Causal
Part
Nature
Code
Cause
Code
Refer to
WebLTS
37501K4XXX**
I3A
ZZ3
Refer to
WebLTS
37501G72XX**
I3A
ZZ3
Refer to
WebLTS
37501G76XX**
I3A
ZZ3
**Refer to actual part number on the battery received but do not include the digits “RM” at the end in causal part number.
Parts Information:
Part Name
Part Number
Model
Kona Electric
*37501-XXXXX
High Voltage
(OS EV)
or
Battery Assembly
Quantity
1
*37501XXXXXRM
Kona Electric
(OS EV)
37501-XXXXRM
refers to a refurbished
battery.
Bolt & Washer
Assy
Kona Electric Electric Vehicle
(OS EV)
Battery System
(only found in Coolant (BSC-1)
vehicles
after 5/7/19
mfg. date)
2020MY~
Ioniq Electric
(AE EV)
Remark
Do not order
the battery.
The correct
battery will be
manually
allocated to
ship to Dealer
after Techline
approval.
NOTES:
*Refer to actual part
number on the battery
received.
Ioniq Electric
(AE EV)
Diagram
37535-K4050
18
37535-Q4050
4
00232-19091
3
Order only for
Kona EV.
All bolts must
be replaced
when battery is
replaced.
Order only for
vehicles with
blue coolant***
(Confirm
coolant color in
the vehicle’s
coolant
reservoir tank)
***Do not order blue coolant for green coolant vehicle, colors cannot be mixed. See page 13.
TSB #: 20-EE-001H-2
Page 2 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
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.

Tools will be shipped from Bosch to any Dealer at their first EV battery replacement service as
a required special tool. Additional or replacement tools thereafter are ordered from Bosch.
PART NAME /
(Part Number)
DIAGRAM
REMARK
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
Fits All Hyundai
EV Battery.
(P/N: 09375-K4100)
Substitute tool is not permitted.
AE EV
(Water Cooling Type)
High Voltage Battery
Pack Transport Hanger
(P/N: 09375-G7100)
TSB #: 20-EE-001H-2
NOTE:
Additional tool to compliment
the above Lifting Fixture
that only applies for
2020MY and later
Ioniq AE EV that
contain coolant.
Page 3 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
NOTE: The following page must be completed by Service Manager and sent to Techline along
with GDS Data Analysis from the Battery BMS System to get approval to release an EV battery.
EV Battery Replacement Required Special Tools Acknowledgment
EV battery replacement requires a special lift table and a high voltage battery lifting fixture(s) to safely
remove and replace large heavy EV batteries. 2020+MY Ioniq AE EV requires the additional hangar.
For your first EV battery order, the following essential tools will be shipped to your dealership and
billed through the Bosch Special Service Tool program, unless otherwise noted in bottom section:
 Propulsion System Lift Table (P/N: HMA52200-A)
$4,395.00*
 High Voltage Battery Lifting Fixture (P/N: 09375-K4100) $920.00*
 Ioniq AE EV (Water Cooling Type) High Voltage Battery Pack Transport Hanger (P/N: 09375G7100) $TBD (NOTE: This additional tool only applies for 2020+MY AE EV cases).
*Price is subject to change and cost of the tools does NOT include shipping and applicable taxes.
The undersigned acknowledges receipt of this notice and understands that the dealer will be billed for
these tools upon an initial order of an EV battery.
Dealer Name: ___________________________________
Dealer Code: ____________
VIN:____________________________________________
Dealer Service Manager:
Print Name:_____________________________________________
Signature:______________________________________
______________________________________________________________
If your Dealership already has the required tools or an equivalent compatible lift table suitable
for EV batteries, please complete this section and contact your District Parts & Service
Manager to approve this section. If your dealership does not have the specific Battery Lifting
Fixture(s) they must be ordered as the only tool specific to fit Hyundai EV batteries.
Please check mark the following to select the tools that your dealership already has:
 Propulsion System Lift Table / Brand:______________ Model Number:__________________
 High Voltage Battery Lifting Fixture (Hyundai P/N: 09375-K4100)
 AE EV (Water Cooling Type) High Voltage Battery Pack Transport Hanger (P/N: 09375-G7100)
I certify that the above mentioned dealer has an equivalent lift table suitable for Hyundai EV models.
Manager, District Parts & Service:
Print Name:____________________________________
Signature:______________________________________
TSB #: 20-EE-001H-2
Page 4 of 15
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 #: 20-EE-001H-2
Continue the above steps page by page until all
Data Analysis pages are captured & saved.
Page 5 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
B-1. Contact Techline at 1-800-325-6604 to establish a Techline Case to request 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).
 EV Battery Required Special Tools Acknowledgment form completed by Dealer Service
Manager.
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.
Techline reviews the required BMS data and EV Battery Special Tools Acknowledgment Form
to ensure the case qualifies for approval of an EV battery replacement.
Once Techline approves, an EV Battery will be shipped out by Mobis to the Dealer. Shipping
can take 2-7 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 (Applicable to Dealer cases of first time EV
battery replacement).
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 #: 20-EE-001H-2
Dual Hyundai and Genesis Dealer:
Page 6 of 15
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 #: 20-EE-001H-2
Page 7 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
F-2. Important Battery Removal Notes:

You must use the SST P/N: HMA52200-A
Propulsion System Lift Table as shown in
the Required Tools section, or an
equivalent Lift Table that was approved by
your DPSM on your completed Tool
Acknowledgment form of page-4.
Place a piece of cardboard on the table top
of 1/8 inch thickness minimum.
All Kona EV and 2020MY~ Ioniq 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.
Clamp the hose at both nipples to prevent
coolant from draining during handling and
shipping of the battery.

All 4 undercover brackets and the
ground strap must be left on the battery
core to be returned (exception is if any is
missing on the replacement battery
received it may be transferred over).
TSB #: 20-EE-001H-2
Page 8 of 15
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
assembly with integrated side panels.

It includes clips at the bottom to secure the
cover to the bottom crate containing 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 #: 20-EE-001H-2
Page 9 of 15
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.
2020MY and later Ioniq AE EV battery must
also use hangar SST P/N: 09375-G7100.
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 #: 20-EE-001H-2
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 10 of 15
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 #: 20-EE-001H-2
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 11 of 15
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 #: 20-EE-001H-2
Page 12 of 15
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
SUBJECT:
Section H applies to all Kona EV and 2020MY~ Ioniq EV which has a battery with coolant:
NOTICE
There are 2 types of Coolant as identified by color. The correct coolant must be identified and
you cannot mix coolant between the 2 types. The blue coolant is a special low conductivity
coolant and is not to be mixed with water, unlike the regular green coolant.
H-1. Fill the P/E cooling system reservoir to the MAX full mark with the following depending on the
type of coolant found in the vehicle as identified by color:
Coolant
Part
Comment
Diagram
Color
Number
Green
Regular
50/50 mix
coolant
with water
Blue
TSB #: 20-EE-001H-2
Use only
Hyundai P/N
00232-19091
Do not mix
with water
Page 13 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
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.
I-1. Perform a test drive for at least 2-3 miles and
make sure vehicle is OK.
TSB #: 20-EE-001H-2
Page 14 of 15
SUBJECT:
ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES
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 and 2020MY~ Ioniq EV battery
with coolant, 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 secured 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-001H-1 or later to schedule pickup by
KBI of the used battery core as soon as
possible. KBI will provide specific instructions.
TSB #: 20-EE-001H-2
Page 15 of 15