22-EV-001H

GROUP
NUMBER
EV SYSTEM
22-EV-001H
DATE
Technical Service Bulletin
MODEL(S)
Kona Electric
(OS EV)
APRIL 2022
KONA EV MOTOR RUMBLE NOISE
SUBJECT:
Description: This bulletin outlines the necessary inspection and repair procedures for certain 20192020MY Kona EV (OS EV) vehicles, exhibiting abnormal rumbling noise from the electric traction
motor.
Applicable Vehicles: Certain 2019-2020MY Kona Electric (OS EV) vehicles produced until
1/19/2021.
Parts Required: (NOTE: Be sure to check producton date of the subject vehicle):
MODEL
PART NAME
Kona Electric
(OS EV)
MOTOR/ROLL MOUNT
BRACKET AND BOLT KIT-A
MOTOR/ROLL MOUNT
BRACKET AND BOLT KIT-B
PART NUMBER
NOTE
Vehicle produced
before 5/13/19
Vehicle produced
5/13/19 or later
36930-0E700FFF
36930-0E710FFF
Warranty Information:
MODEL
Kona
Electric
(OS EV)
CAUSAL
PART
OP
CODE
OP CODE
OPERATION
36930F00
KIT REPLACEMENT
(2 TEST DRIVES)
3.2
M/H
36930F01
KIT INSPECTION AND
REPLACEMENT +
MOTOR/REDUCTION GEAR
REINSTALLATION (3 TEST
DRIVES)
8.8
M/H
36930F02
KIT INSPECTION AND
REPLACEMENT + MOTOR
REPLACEMENT (3 TEST DRIVES)
36930F03
KIT INSPECTION AND
REPLACEMENT + REDUCTION
GEAR REPLACEMENT (3 TEST
DRIVES)
8.8
M/H
36930F04
KIT INSPECTION AND
REPLACEMENT +
MOTOR/REDUCTION GEAR
REPLACEMENT (3 TEST DRIVES)
8.8
M/H
4450018EA1
8.8
M/H
NATURE CAUSE
CODE
CODE
Q55
ZZ1
NOTE: Normal Warranty Applies.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
KONA EV MOTOR RUMBLE NOISE
SUBJECT:
Troubleshoot Flow Diagram:
Test drive
(Check rumble
noise)
Replace mounting bolts of
traction motor/reduction
gear and brackets
(2 types)
Test drive
(Check rumble
noise)
KIT replacement
OK
Vehicle out
Rumble Noise generation
Noise not
Isolated
Inspect
traction motor/
reduction gear
Remove traction
motor/reduction gear
From vehicle
Inspect traction motor/reduction
gear and assemble vertically
Replace traction motor
and reassemble
vertically
Test drive
(Check noise)
모터/감속기
Noise can be isolated to
a particular component
Replace traction motor
or reduction gear
OK
Test drive
(Check noise)
OK
Vehicle out
Replace traction motor or reduction gear
NOTICE
• Always attach noise records as claim evidence. Claims without noise records may not be
accepted.
NOTICE
• Refer to the shop manual for high voltage safety precautions.
• Disconnect the battery’s negative (-) terminal before servicing.
• Perform the high voltage cut-off work before servicing.
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KONA EV MOTOR RUMBLE NOISE
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Service Procedure:
1.
Test drive the vehicle. Creep in “D” and slowly accelerate/decelerate within speeds of 25-50
MPH, inspect for rumble noise generation from the traction motor and may especially be
noticeable on deceleration.
2.
If rumble is generated, place the car on a lift and proceed to disconnect the high voltage
system.
!
WARNING
• Refer to the shop manual section for high voltage precautions:
Motor System > High Voltage Battery Handling Guide
• When working on the high voltage system, make sure that you are familiar and comply
with the “Safety Precautions, Cautions and Warnings.” If you do not comply with the
safety procedures, serious injury or death may occur.
3.
Disconnect the service interlock connector
(A).
NOTICE
Be sure to wait for at least 3
minutes before proceeding to the
next step.
A
4.
If service interlock connector is unable to be
disconnected, proceed to service procedure
steps 5-9. Otherwise, proceed with step 10.
5.
Turn OFF the ignition switch and disconnect
the negative (-) cable of the 12V battery.
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6.
KONA EV MOTOR RUMBLE NOISE
Remove the trunk luggage board cover (B).
B
7.
Remove the rear seat.
Refer the shop manual section for complete
service procedure:
Body (Interior and Exterior) > Rear Seat
8.
Remove the service plug service cover (C).
C
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9.
KONA EV MOTOR RUMBLE NOISE
Remove the service plug (D).
D
A. Roll Mount Replacement
10.
11.
Place the vehicle on a lift and remove the
under cover.
Refer the shop manual section for complete
service procedure:
Motor System > Motor Assembly >
Support the reduction gear assembly with a
jack.
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12.
KONA EV MOTOR RUMBLE NOISE
Replace the roll mount.
Tightening Torque:
Bolt E: 79.6 – 94.1 lb-ft (107.9 – 127.5 Nm)
Bolt F: 47.0 – 61.5 lb-ft (63.8 – 83.4 Nm)
F
E
B. Motor Mounting Support Bracket Replacment
1.
Support the motor with a jack.
2.
Remove the motor mounting support bracket,
outlined in the figure.
Tightening Torque:
Nut G: 57.9 – 72.4 lb-ft (78.5 – 98.1 Nm)
Nut H: 43.4 – 54.3 lb-ft (58.9 – 73.6 Nm)
Bolt I: 43.4 – 54.3 lb-ft (58.9 – 73.6 Nm)
G
I
H
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3.
Remove the motor support bracket (J).
J
4.
Remove the mass (K) from the new motor
support bracket.
5.
Replace the motor support bracket with a
new one.
K
NOTICE
First, tighten the top side bolt that
is outlined in the figure. After
inserting the bracket into the lower
side, pretighten the bolt.
7.
Assemble the mass (K) to the motor mount’s
top side. Ensure the protrusion faces
towards the engine compartment.
K
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KONA EV MOTOR RUMBLE NOISE
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C. Motor Mounting Bolt Replacement
1.
Remove the high voltage junction box (L)
following the repair procedures in the shop
manual.
Battery Control System > High Voltage
Distributing System > High Voltage
Junction Box
L
Be sure to comply with the specified (On
Board Charger) OBC and Electronic Power
Control Unit (EPCU) torque values for the
mounting bolts.
Tightening Torque:
Bolt (A): 2.9 – 4.3 lb-ft (3.9 – 5.9 Nm)
Bolt (B): 6.5 – 7.2 lb-ft (8.8 – 9.8 Nm)
NOTICE
Tighten the bolts at a right angle to
avoid striping the threads.
2.
Loosen the 8 mounting bolts of the traction
motor and reduction gear regardless of
order.
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3.
KONA EV MOTOR RUMBLE NOISE
The tightening order of the traction motor and
reduction gear mounting bolts is shown in the
figure to the right.
7
2
8
4
6
KIT A specification: Vehicles Produced
before 5/13/19
4.
3
1
5
KIT A Specification: Vehicles Produced
5/13/19 or later
Replace the mounting bolts one by one
following the tightening order.
Tightening Torque:
65.8 – 71.6 lb-ft (89.3 – 97.1 Nm)
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KONA EV MOTOR RUMBLE NOISE
5.
Reinstall the removed parts in reverse order
of removal.
6.
Test drive the vehicle and inspect for rumble
noise.
7.
➢ If rumble noise is resolved the service
procedure is complete.
➢ If the rumble noise is not acceptable,
perform the additional work following the
procedures below.
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KONA EV MOTOR RUMBLE NOISE
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D. Removal of the Traction Motor/Reduction Gear
1.
Place the car on a lift and proceed to disconnect the high voltage system.
!
WARNING
• Refer to the shop manual section for high voltage precautions:
Motor System > High Voltage Battery Handling Guide
• When working on the high voltage system, make sure that you are familiar and comply
with the “Safety Precautions, Cautions and Warnings.” If you do not comply with the
safety procedures, serious injury or death may occur.
2.
Disconnect the service interlock connector
(M).
NOTICE
Be sure to wait for at least 3
minutes before proceeding to the
next step.
M
4.
If service interlock connector is unable to be
disconnected, proceed to service procedure
steps 5-9. Otherwise, proceed with step 10.
5.
Turn OFF the ignition switch and disconnect
the negative (-) cable of the 12V battery.
6.
Remove the trunk luggage board cover (N).
N
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7.
KONA EV MOTOR RUMBLE NOISE
Remove the rear seat.
Refer the shop manual section for complete service procedure:
Body (Interior and Exterior) > Rear Seat
8.
Remove the service plug service cover (O).
O
9.
Remove the service plug (P).
P
10.
Remove the under cover.
Refer the shop manual section for complete service procedure:
Motor System > Motor Assembly > Under Cover.
11.
Drain the engine coolant.
Refer the shop manual section for complete service procedure:
Cooling System > Electric & High Voltage Battery Cooling System > Coolant
12.
Recover the A/C refrigerant.
Refer the shop manual section for complete service procedure:
Heating, Ventilation And Air Conditioning >Air Conditioning System
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13.
KONA EV MOTOR RUMBLE NOISE
Remove the 12V auxiliary battery and tray.
Refer the shop manual section for complete service procedure:
Vehicle Control System > Electric Power Control Unit (EPCU) > Auxiliary 12V Battery
14.
Slightly loosen the front wheel nuts.
15.
Remove the front wheel and tire (Q).
Q
16.
Remove the caulking nut (R) from the front
hub.
Tightening Torque:
202.6 – 217.1 lb-ft (274.7 – 294.3 Nm)
R
17.
Remove the tie rod end ball joint using SST:
09568-1S100.
• Remove the split pin and castle nut (S).
• Remove the tie rod end ball joint (T) using
SST: 09568-1S100
T
S
Tightening Torque:
57.9 – 72.4 lb-ft (78.5 – 98.1 Nm)
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18.
KONA EV MOTOR RUMBLE NOISE
Remove the lower arm ball joint using SST:
09568-1S100
• Remove the snap pin and castle nut (U).
• Remove the lower arm ball joint (V) using
SST: 09568-1S100.
19.
Remove the front drive shaft assembly (both
sides).
20.
Disconnect the radiator upper hose (W).
W
21.
Disconnect the radiator lower hose (X).
X
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22.
KONA EV MOTOR RUMBLE NOISE
Disconnect the 3-way valve quick connector
(Y).
Y
23.
Disconnect the 3-way valve outlet hose (Z) at
the battery side.
Z
24.
Disconnect the air conditioner pressure
transducer connector (AA) and remove the
air conditioner pipe (AB).
AB
AA
25.
Remove the air conditioner pipe (AC).
AC
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26.
KONA EV MOTOR RUMBLE NOISE
Remove the air conditioner pipe (AD).
AD
27.
Remove the OBC cable bracket (AE) and then
disconnect the connector (AF).
AF
AD
28.
Disconnect the slow charger (high voltage
junction box) cable connector (AG).
AG
29.
Disconnect the PTC (Positive Temperature
Coefficient) high voltage cable connector
(AH).
AH
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30.
KONA EV MOTOR RUMBLE NOISE
After disconnecting the high voltage cable
(AI) of the high voltage battery assembly,
remove the bracket (AJ).
AI
AJ
31.
Disconnect the wiring harness from the PE
room and disconnect the battery sensor
connector (AK).
32.
Remove the fuse box cover (AL).
33.
Disconnect the fuse box main wiring
connector (AM).
AK
AL
AM
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34.
KONA EV MOTOR RUMBLE NOISE
Disconnect the fuse box wiring cable (AN).
AN
34.
Disconnect the inlet water temperature sensor
connector (AO).
AO
35.
Disconnect the 3-way valve (For Electrical
Devices) inlet hose (AP).
AP
36.
Loosen the 3-way valve mounting bolts (AQ).
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AQ
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37.
KONA EV MOTOR RUMBLE NOISE
Remove the reservoir tank (AR).
AR
38.
Remove the main wiring protector (AS).
39.
Remove the reduction gear chassis ground
cable (AT).
AS
Tightening Torque:
19.5 – 23.9 lb-ft (26.5 – 32.4 Nm)
AT
40.
Remove the traction motor chassis ground
cable (AU).
AU
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41.
KONA EV MOTOR RUMBLE NOISE
Disconnect the EWP outlet hose (AV) at the
battery side.
AV
42.
Remove the rear roll mounting bracket,
outlined in the figure.
Tightening Torque:
Bolt (B): 79.6 – 94.1 lb-ft (107.9 – 127.5 Nm)
Bolt (C): 47 – 61.5 lb-ft (63.8 – 83.4 Nm)
43.
Loosen the refrigerant pipe mounting bolt
(AW).
AW
Tightening Torque:
5.8 – 8.7 lb-ft (7.8 – 11.8 Nm)
44.
Loosen the refrigerant pipe mounting nut
(AX), then remove the refrigerant pipe (AY).
Tightening Torque:
5.8 – 8.7 lb-ft (7.8 – 11.8 Nm)
AY
AX
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45.
Safely support the traction motor and
reduction gear assembly with a floor jack.
46.
Remove the traction motor mounting support
bracket, outlined in the figure.
Tightening Torque:
Nut (B): 57.9 – 72.4 lb-ft (78.5 – 98.1 Nm)
Bolt (C): 43.4 – 54.4 lb-ft (58.9 – 73.6 Nm)
Nut (D): 43.4 – 54.4 lb-ft (58.9 – 73.6 Nm)
47.
Loosen the reduction gear mounting bolts
(AZ).
Tightening Torque:
79.6 – 94.1 lb-ft (107.9 – 127.5 Nm)
48.
AZ
Lift up the vehicle to remove the traction
motor and reduction gear assembly.
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49.
KONA EV MOTOR RUMBLE NOISE
Disconnect the water outlet hose (BA).
BA
50.
Disconnect the compressor high voltage
cable connector (BB).
BB
51.
Remove the OBC side cover (BC) and the
EPCU side cover (BD).
Tightening Torque:
2.9 – 4.3 lb-ft (3.9 – 5.9 Nm)
BC
BD
52.
Loosen the ODC mounting bolts (BE) and the
EPCU mounting bolts (BF).
BE
Tightening Torque:
Bolt (A): 2.9 – 4.3 lb-ft (3.9 – 5.9 Nm)
Bolt (B): 6.5 – 7.2 lb-ft (8.8 – 9.8 Nm)
BF
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53.
KONA EV MOTOR RUMBLE NOISE
Loosen the mounting bolts (BG), then
remove the high voltage junction box (BH).
BH
Tightening Torque:
11.6 – 17.4 lb-ft (15.7 – 23.5 Nm)
BG
54.
55.
Loosen the refrigerant pipe mounting bolt
(BI).
BI
Disconnect the traction motor inlet hose (BJ).
BJ
56.
Disconnect the coolant hose (BK), then
remove the coolant pipe (BL).
Tightening Torque:
5.8 – 7.2 lb-ft (7.8 – 9.8 Nm)
BL
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BK
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57.
KONA EV MOTOR RUMBLE NOISE
Disconnect the control board signal
connector (BM).
BM
58.
Loosen the OBC mounting bolts, then
remove the OBC (BN).
59.
Loosen the mounting bolt (BO), then
disconnect the EPCU (+) cable (BP).
BN
BP
BO
60.
Disconnect the Low Voltage (-) cable (BQ)
and the EWP (Electric Water Pump) outlet
hose (BR).
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BQ
BR
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61.
KONA EV MOTOR RUMBLE NOISE
Disconnect the EWP connector (BS)
BS
62.
Disconnect the EWP inlet hose (BT).
BT
63.
Disconnect the EPCU connector (BV).
BV
64.
Loosen the EWP mounting bolts (BW) and
remove the EWP with the bracket.
Tightening Torque:
13.0 – 15.9 lb-ft (17.7 – 21.6 Nm)
BW
BW
BW
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BW
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65.
KONA EV MOTOR RUMBLE NOISE
Loosen the mounting bolts and then remove
the 3-phase cover assembly (BX).
BX
Tightening Torque:
2.3 – 4.3 lb-ft (3.9 – 5.9 Nm)
66.
67.
Loosen the EPCU mounting bolts, then
remove the EPCU (BY).
Loosen the water pipe mounting bolts (BZ),
then remove the water pipe (CA) with the
3-way valve.
BY
BZ
CA
68.
Remove the main wiring and protector from
the traction motor and reduction gear
assembly.
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69.
KONA EV MOTOR RUMBLE NOISE
Loosen the refrigerant accumulator pipe
bracket mounting bolt (CB).
CB
70.
Disconnect the traction motor inlet hose
(CC).
CC
71.
Loosen the heat pump 3-way valve mounting
bolts, then remove the heat pump 3-way
valve (CD).
CD
72.
Remove the traction motor support bracket
(CE).
Tightening Torque:
65.8 – 71.6 lb-ft (89.3 – 97.1 Nm)
CE
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73.
KONA EV MOTOR RUMBLE NOISE
Loosen the reduction gear’s upper mounting
bolts (CF).
Tightening Torque:
65.8 – 71.6 lb-ft (89.3 – 97.1 Nm)
CE
74.
Loosen the lower reduction gear bolts (CF)
and remove the traction motor assembly from
the reduction gear.
Tightening Torque:
65.8 – 71.7 lb-ft (89.3 – 97.1 Nm)
E. Traction Motor and Reduction Gear Noise Inspection Preparation
1.
Place a plug in the drive shaft hole to prevent
reduction gear oil from being spilled.
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2.
Secure the traction motor in place so it does
not move around during inspection.
F. Traction Motor Noise Inspection
1.
Connect a 5mm hexagonal tip to the taper
plug at the end of the traction motor shaft
and carefully rotate it counterclockwise with a
power tool.
NOTICE
• During the beginning of
rotation, slowly rotate the
shaft by hand and by power
tool until inertial forces are
overcome.
• If the initial torque is strong,
the taper may be damaged.
• Do not use an air impact
wrench.
2.
3.
When motor shaft reaches a constant speed
after rotating it for about 5 seconds or more,
remove the tool and inspect for noises being
generated in the motor shaft.
If noise is generated from the traction motor,
replace it.
G. Reduction Gear Noise Inspection
1.
After removing the inhibitor switch (SBW),
use a 12mm socket wrench to shift the gear
into “N”.
• “N” Range: Counterclockwise
• “P” Range: Clockwise
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2.
Inspect by rotating the reduction gear input
shaft by hand.
➢ Normal: No noise or severe vibration
occurs during rotation:
o Replace the Traction Motor.
➢ Replace the reduction gear if abnormal
noise or vibration is clearly identified.
H. Reduction Gear Vertical Reassembly
1.
After inspecting for noise and replacing the
part generating noise or vibrations,
reassemble the traction motor and reduction
gear following the procedures below.
NOTICE
If no noise is heard during
traction motor / reduction gear
inspection, replace the Traction
Motor only.
2.
Stand the traction motor vertically.
3.
Stand the motor shaft upwards from the
ground, then reassemble the reduction gear.
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4.
KONA EV MOTOR RUMBLE NOISE
Tighten the improved bolts in the specified
order as shown on the figure to the right.
Tightening Torque:
65.8 – 71.6 lb-ft (89.3 – 97.1 Nm)
5.
Reinstall parts in reverse order of
disassembly.
6.
The service procedure is complete.
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