TSB_ELE310

GROUP
MODEL
ELE
2015-2017MY
Soul EV (PS EV)
NUMBER
DATE
310
October 2023
TECHNICAL SERVICE BULLETIN
HIGH-VOLTAGE BATTERY PACK AND
SUBJECT:
BATTERY MANAGEMENT SYSTEM
This bulletin provides information regarding the replacement of the High-Voltage Battery Pack Assembly (HV
BPA) on some 2015-2017MY SOUL EV (PS EV) produced from July 15, 2014 through June 30, 2017 which were
not included in SC267 Safety Recall Campaign. The Battery Management System (BMS) and Voltage &
Temperature Sensor Wiring Harness (VTSWH) will need to be replaced along with the ‘new’ HV BPA, when
replacing an ‘originally’ equipped HV BPA on the applicable vehicles. In addition, the BMS Software will also
need to be upgraded to complete the repair. Follow the procedure outlined in this publication to replace the
BPA, BMS, VTSWH and upgrade the BMS software on the applicable vehicle.
 NOTICE
A Technical Service Bulletin is a field fix repair program without customer notification that may be
performed during the warranty period. Any dealer requesting to perform this repair outside the
warranty period will require DPSM approval.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Page 2 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
Flowchart:
Vehicle In
For BPA Replacment
(Not Included
in SC267)
BPA +
BMS + VTSWH
Replacement
(TL PWA Process)
Perform
BMS S/W Upgrade
Vehicle Out
 IMPORTANT
The new BPA is equipped with an “old” type harness. Be sure to install the “new” type harness.
Techline PWA is required for HV BPA replacement. Dealer should follow the process included in
TSB ELE044 and obtain TL PWA . Claim submission concerns WILL occur if the dealer does not
obtain TL PWA for HV BPA replacement.
Operation Descriptions:
•
BMS Software (BMS S/W)
•
High Voltage Battery Pack Assembly (HV BPA)
•
Voltage & Temperature Sensor Wiring Harness (VTSWH)
•
Battery Management System (BMS)
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 3 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
WARNING
Be sure to read and follow the ‘General Safety Information and Caution’, the ‘High Voltage Shut-
Off Procedures’ and ‘High Voltage Battery Handling Guide’ instructions outlined on KGIS before
doing any work related with the high voltage system. Failure to follow the safety instructions may
result in serious electrical injuries.
BMS ECU Replacement Procedure:
1.
Remove the BPA upper case (A) by referring to
“EV Battery System → High Voltage Battery
System
→
Case
→
Repair
procedures
(Removal)” in the applicable Shop Manual on
KGIS. Refer to KGIS for bolt/nut torque specs.
TECH TIP
Mark the six (6) ‘ground’ bolts and
their location to prevent mixing with
regular bolt prior to reassembly.
Regular Bolt (8)
Ground Bolt (E)
Ground Bolt (E): 6 ea.
Regular Bolt (8): 35 ea.
2.
Replace the BMS ECU by referring to “EV
Battery System → High Voltage Battery
Control
System
→
Battery
Management
System (BMS) ECU → Repair procedures
(Removal)” in the applicable Shop Manual on
KGIS.
3.
Proceed
to
the
‘BPA
and
Voltage
&
Temperature Sensor Wiring Harness (VTSWH)
Replacement Procedure’ on page 10.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 4 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
WARNING
Be sure to read and follow the ‘General Safety Information and Caution’, the ‘High Voltage Shut-
Off Procedures’ and ‘High Voltage Battery Handling Guide’ instructions outlined on KGIS before
doing any work related with the high voltage system. Failure to follow the safety instructions may
result in serious electrical injuries.
BPA and VTSWH Replacement Procedure:
1.
Remove the HV BPA by referring to “EV
Battery System → High Voltage Battery
System → Battery Pack Assembly → Repair
procedures (Removal)” in the applicable Shop
Manual on KGIS.
 IMPORTANT
15-17MY ONLY new BPA is equipped
with an “old” type harness. Be sure to
install the “new” type harness.
Note: SST OK375 E4300 BPA lifting jig and
crane jack (A) are required.
 NOTICE
Place the removed BPA on a clean flat
surface. Dealer should follow the
process included in TSB ELE044 and
obtain TL PWA.
Note: The battery pack assembly (BPA)
consists of two (2) (left and right) battery
packs.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 5 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
2.
Remove the existing voltage and temperature
sensor wiring harness (VTSWH) retaining
screws for both (left and right) on the ‘new’
battery packs assemblies.
3.
Replace the two voltage temperature sensor
wire harnesses (VTSWH) with the ‘new’ parts.
Note: The new harness is different for the
removed harness when compared side by side.
4.
During
re-assembly,
insert
the
battery
temperature sensor into the battery pack
lower side area shown.
Connect the outside temperature sensor
connector where shown.
Note: Some vehicles may have a remaining
temperature sensor connector hole. If so,
disregard, no need to connect to it.
5.
Reinstall all removed parts in the reverse order
of removal.
6.
Perform the BCM Software Upgrade as
outlined on page 6, in ‘Manual Mode’ only.
7.
Confirm normal vehicle operation.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 6 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
ECU Upgrade Procedure:
To correct this condition, the ECU should be reprogrammed using the KDS
download, as described in this bulletin.
Upgrade Event Name
*696. 15-17MY PS EV BMS Diagnostic Logic Enhancement Touch
*Note: Event #696 for 15-17MY PS EV will not appear in the upgrade events list
as it needs to be performed in ‘Manual Mode’ only.
 NOTICE
•
Confirm a fully charged battery (12.3 volts or higher is necessary) is used or utilize a fully
charged jump starter box connected to the battery.
•
Ensure the KDS GDS is sufficiently charged at 60% or higher prior to reflash.
•
All ECU upgrades must be performed with the ignition set to the ‘ON’ position unless otherwise
stated.
•
Damaged VCI II units should not be used and promptly replaced.
•
Be careful not to disconnect the VCI-II connected to the vehicle during the ECU upgrade
procedure.
•
DO NOT start the engine during ECU upgrade.
•
DO NOT turn the ignition key ‘OFF’ or interrupt the power supply during ECU upgrade.
•
When the ECU upgrade is completed, turn the ignition ‘OFF’ and wait 10 seconds before
starting the engine.
•
ONLY use approved ECU upgrade software designated for the correct application.
 IMPORTANT
It is recommended to ALWAYS check the Electronic Parts Catalog (EPC) to locate the ECU Part
Number respective to Auto/Manual Mode ROM IDs. DO NOT reference the parts label affixed to
the ECU.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 7 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
 NOTICE
Before attempting an ECU upgrade on any Kia model, make sure to first determine whether the
applicable model is equipped with an immobilizer
security system. Failure to follow proper
procedures may cause the PCM to become inoperative after the upgrade and any claims associated
with this repair may be subject to chargeback.
ROM ID INFORMATION TABLE:
Upgrade Event #696 (15-17MY)
Model
SYSTEM
PS EV
BMS
15-17MY*
IMMO
ECU P/No.
Yes
ROM ID
Previous
New
37513 E4251
4604
4704*
37513 E4201
4606
4706*
Note: *Perform Event #696 in ‘Manual Mode’ only .
To verify the vehicle is affected, be sure to check the Calibration Identification of the vehicle's ECM ROM ID
and reference the Information Table as necessary.
 NOTICE
Prior to performing the ECU upgrade, be sure to check that the KDS is fully charged.
1.
Connect the VCI-II to the OBD-II connector,
located
under
the
driver’s
side
of
the
instrument panel.
 NOTICE
The ECU upgrade function on KDS
operates wirelessly. It is not necessary
to perform the upgrade via USB cable.
2.
With the ignition ON, turn ON the KDS tablet.
Select ‘KDS’ from the home screen.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 8 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
3.
Confirm communication with VCI (A) and then
configure the vehicle (B) using the ‘AUTO VIN’
(C) feature.
B
A
C
4.
Select ‘ECU Upgrade’.
5.
The KDS will check the server for recently
uploaded
Events
and
then
automatically
download Upgrade Event #697.
 NOTICE
The vehicle must be identified in
Vehicle Selection to download an
Event for that vehicle.
6.
KDS
screenshot
shown
above
is
for
demonstration purposes only. Events shown in
screenshot are not applicable to this bulletin.
Select ‘Manual Mode’
Refer to page 11 for instructions.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 9 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
7.
Select ‘BMS’ system and confirm the applicable
Event #696.
D
Note: Event #696 for 15-17MY PS EV will not
appear in the upgrade events list as it needs to
be performed in ‘Manual Mode’ only.
8.
The ECU upgrade will begin and the progress
of the upgrade will appear on the bar graph.
E
Upgrade part (1/2) (E) will download the
upgrade event to the VCI-II. Upgrade part (2/2)
(F) will upgrade the ECU.
CAUTION
F
Do not touch the system buttons (like
‘Back’,
‘Home’,
‘etc.’)
while
performing ECU Upgrade.
9.
If a “Communication Fail” screen appears, verify
that the VCI-II and KDS are communicating
properly. Select ‘OK’ and restart the from step
4.
 NOTICE
If an error notice continues to appear
or
if
the
upgrade
cannot
be
performed, DO NOT disconnect the
KDS/VCI-II. Contact GIT America Help
Desk at (888) 542-4371 or Techline.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 10 of 13
SUBJECT:
10.
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
When instructed on the KDS, turn the ignition
OFF for ten (10) seconds then back on. Select
‘OK’ to continue.
11.
Once the upgrade is complete, select ‘OK’ to
finalize the procedure.
12.
When prompted, select ‘YES’ to check for
Diagnostic Trouble Codes (DTC) and erase any
DTCs stored such as EPS, ESC, and TPMS that
may have been set during the upgrade.
13.
Start the engine to confirm normal operation of
the vehicle.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 11 of 13
SUBJECT:
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
Manual Upgrade Procedure:
 NOTICE
The manual upgrade should ONLY be performed if the automatic upgrade fails.
If the automatic upgrade fails, turn the ignition ‘OFF’ for about 10 seconds then place it back in
the ‘ON’ position to reset the control unit BEFORE performing manual upgrade.
See table below for ‘Manual Mode’ passwords.
Manual Mode ECU Upgrade Passwords
Menu
Password
PS EV BMS (15~17MY, +electric heater): 37513-E4251
1524
PS EV BMS (15~17MY, -electric heater): 37513-E4201
3751
Note: *Perform Event #696 in ‘Manual Mode’ only.
1.
Within the ECU Upgrade screen displayed, select Manual Mode.
2.
Select the ‘BMS’ system under the System selection menu. Select Upgrade Event #696 and select
Upgrade to continue.
3.
Select the appropriate control unit part number with reference to the ROM ID Information Table on
page 3, and select OK.
4.
Enter the appropriate password from the Manual Mode password table above and select OK.
5.
The upgrade will begin and the progress of the upgrade will appear on the bar graph.
6.
When instructed on the KDS, turn the ignition OFF for ten (10) seconds then back on. Select OK.
7.
Once the upgrade is complete, select OK to finalize the procedure.
8.
When prompted, select YES to check for Diagnostic Trouble Codes (DTC) and erase any DTCs stored
such as EPS, ESC, and TPMS that may have been set during the upgrade.
9.
Start the engine to confirm proper operation of the vehicle.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
Page 12 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
AFFECTED VEHICLE RANGE:
Model
Production Date Range
15-17MY Soul EV (PS EV)
July 15, 2014 to June 30, 2017
REQUIRED TOOL:
Tool Name
Part Number
Figure
Comments
To be used along
BPA Lifting Jig
OK375 E4300
with an engine
crane/hoist.
REQUIRED PART:
Part Name
Part Number
Volt. & Temp. Sensor
Figure
Qty.
Comment
37561 E4210FFF
1
Left Side
37561 E4220FFF
1
Right Side
Wire Harness (VTSWH)
(New for 15-17MY only)
Battery Management
37513 E4201FFF
Non-Heated
1
System (BMS)
(15-17MY only)
37513 E4251FFF
Heated
Battery Pack
37510 E4202R*
Non-heated
Assembly (BPA)*
(15-17MY only are equipped
with an original/old VTSWH)
1
37510 E4252R*
Heated
*Note: The replacement part numbers will require a VIN entry for parts ordering. DO NOT order these parts
for stocking purposes, related to this Campaign. Supply is very limited. Until supply stabilizes, please confirm
part availability before scheduling customers.
IMPORTANT: The parts listed below DO NOT required replacement unless damaged or lost during removal.
Case Gasket
(15-19MY)
37528 E4000FFF
N/A
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023
1
Replace only
if damaged
Page 13 of 13
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
WARRANTY INFORMATION:
N Code: W11 C Code: ZZ4
MY
Claim
Type
Causal P/N
Qty.
Repair
Labor Op
Op
Replacement
Description
Code
Time
P/N
BPA+BMS
1517MY
W
37510
0
E4000
Replacement
+VTSWH Swap
+ BMS S/W Upgrade
Qty.
37561 E4210FFF
1
37561 E4220FFF
1
37510 E4202R
37510F05
3.3
or
M/H
37510 E4252R
1
37513 E4201FFF
or
37513 E4251FFF
1
37528 E4000FFF*
1
Note: Techline PWA is required for HV BPA replacement. Dealer should follow the process included in
TSB ELE044 and obtain TL PWA . Claim submission concerns WILL occur if the dealer does not obtain
TL PWA for HV BPA replacement.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 Soul EV (PS EV) October 2023