23-01-073H-1

GROUP
Technical Service Bulletin
NUMBER
CAMPAIGN
23-01-073H-1
DATE
MODEL(S)
October 2023
KONA ELECTRIC
(OS EV)
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
SUBJECT:
This TSB supersedes TSB 23-01-073H with updated part tables for 19-20 MY vehicles.
 IMPORTANT
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.
Access the “Vehicle Information” screen via WEBDCS to identify open campaigns.
Description: Certain 19-23MY Kona Electric (OS EV) vehicles may experience a condition of EV
warning light ON with DTC P1AA6 to P1AAF found stored. The Battery Management System (BMS)
software update will be performed to enhance battery diagnostics logic.
Flowchart summary of the service procedure is provided on page 2 summarized as follows:
• Vehicles that do not have EV Warning Light On will only need the BMS software update.
• Certain vehicles incurring EV Warning Light On and DTC P1AA6 found stored with Freeze Frame
Data Information Code 1=128 will only require the BMS Update.
• Certain other DTC P1AA6 Information Code 1-2 values or DTC P1AA7 to P1AAF will require the
Battery System Assembly (BSA) to be replaced and then the BMS Update to be performed.
Applicable Vehicles (Certain):
• 2019-23MY Kona Electric (OS EV) produced from 8/28/2018 to 3/8/2023
GDS Information:
System
Event #
Description
OS EV NEW LOGIC (RDV) BMS UPGRADE
BMS
999*
* or select the latest available Event # that displays in GDS.
Warranty Information:
MODEL
OP CODE
OP NAME
CAUSAL
PART
OP TIME
Kona
Electric
(OS EV)
30D055R1
DTC (INFO CODE) CHECK AND
BATTERY MANAGEMENT
SYSTEM SOFTWARE UPDATE
375A0K4000
0.4 M/H
BSA REPLACE
Refer to
Pages 9-10
Refer to
pages 9-10
Refer to
pages 9-10
NATURE
CAUSE
I3A
ZZ3
NOTE 1: The BMS software update and if necessary BSA replace are to be submitted on the Claim
Entry Screen as "Campaign" type.
NOTE 2: If a part is found in need of replacement while performing this campaign and the affected
part is still under warranty, submit a separate claim using the same repair order. If the affected part is
out of warranty, submit a Prior Approval request for goodwill consideration prior to performing work.
NOTE 3: This TSB includes Repair validation photos. Op times including VIN, Mileage, and Repair
validation photos as outlined in the Digital Documentation Policy.
NOTE 4: Each BSA replacement labor op code will include reimbursement for bolts, washers, and
coolant. Please refer to TSB 23-EV-001H parts information chart for the applicable part numbers.'
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
Table Of Contents:
Section
Pages
A
4-5
B
6-8
C
8-10
Description
DTC CHECK
BMS SOFTWARE UPDATE
BSA REPLACE (only when applies)
Summary of Service Procedure Flow:
TSB #: 23-01-073H-1
Page 2 of 10
SUBJECT:
SUBJECT:
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
A. DTC CHECK
A1.
Perform BMS system Fault Search by GDS.
A2.
Check for any of DTC P1AA6, P1AA7, P1AA8, P1AA9, P1AAA, P1AAB, P1AAC, P1AAD,
P1AAE or P1AAF found stored as an active or history DTC?
➢ No – (None of the above listed DTC are found stored):
Go to section B - Perform BMS Software Update.
➢ Yes – (DTC P1AA6 is found stored):
Go to next step A3. - Check the DTC P1AA6 Freeze Frame Information Code 1-2
values to determine next steps.
➢ Yes – (Any of DTC P1AA7, P1AA8, P1AA9, P1AAA, P1AAB, P1AAC, P1AAD, P1AAE
or P1AAF are found stored):
Go to section C. - Take STUI photo of Freeze Frame Data, Replace BSA and perform
BMS Update if needed.
A3.
Check the DTC P1AA6 Freeze Frame Data and locate Information Code1-2:
TSB #: 23-01-073H-1
Page 3 of 10
SUBJECT:
SUBJECT
A4.
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
Find the DTC in the chart below,
….. then if DTC P1AA6 also check the Information Codes1-2 values,
………. then find the corresponding value in the last column “BSA Replace?”:
➢ “BSA Replace?” = NO – Go to section B. (BMS Update only)
➢ “BSA Replace?” = YES – Go to section C. (BSA Replace and BMS Update)
➢ “BSA Replace?” = Techline Review (Whether or not BSA is to be replaced will be
decided after Techline review of the BMS Data with Engineering).
Battery Incident
Condition
Early BMS Software
Later BMS
Software
Info
code 1
Info
code 2
DTC
1
-
P1AA700
YES
2
-
P1AA800
YES
4~64
-
P1AA900
YES
DTC
Cell voltage deviation err
or
Insulation resistance erro
r
Abnormal cell voltage ch
ange after charging
Abnormal current change
during charging (CV secti
on)
128
P1AA6
00
BSA Replace?
P1AA600- NO
-
P1AAA00
P1AAA00
*Techline review
Overtemperature
-
1
P1AAB00
YES
Overvoltage
-
2
P1AAC00
YES
Low voltage
Battery temperature
deviation error
MAVD
-
4
P1AAD00
YES
-
8
P1AAE00
YES
-
16
P1AAF00
YES
-
-
P1AB000
*Techline review
RDV
-
NOTE: *Techline review with Engineering to decide if BSA replace based on BMS data
TSB #: 23-01-073H-1
Page 4 of 10
SUBJECT:
SUBJECT:
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
B. BMS SOFTWARE UPDATE
B1.
! WARNING
GDS Vehicle Battery Voltage:
• If the voltage is below 12 volts as per the GDS warning, then select Back and run
the vehicle at least 20 minutes to reach an adequate battery state of charge to
prevent an ECU Update failure. Cycle the ignition OFF/ON before retrying the ECU
update again.
i Information
GDS ECU Updates must be performed in Auto Mode.
• If ECU Update starts but then fails in Auto Mode, perform update in Manual Mode
to recover.
• Turn off ignition for 30 seconds and try Manual Mode recovery.
• If unsuccessful, re-attempt Manual Mode after disconnecting the cables from the
12V battery terminals and performing cap discharge (connecting bar or heavy wire
between “+” to “-“ cables).
B2.
Perform the BMS Update in Auto Mode.
Use the Auto Mode ID Check to verify the BMS
ROM ID before updating the software.
TSB #: 23-01-073H-1
Page 5 of 10
SUBJECT:
SUBJECT
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
B3.
After the ECU Upgrade process shows 100% complete, cycle the ignition key to OFF for at least
10 seconds to reset the control unit.
B4.
Take a screenshot of the ECU Update complete screen and upload to STUI.
STUI
Take a screenshot of the ECU Update
Complete screen using your particular
tablet’s screenshot save method and
upload to STUI.
EXAMPLE
ROM ID Information table:
VEHICLE
SYSTEM
P/NO
375A0-K4052
OS EV
BMS
375A0-K4002
TSB #: 23-01-073H-1
ROM ID
OLD
6400
6500
6700
6730
6740
6770
6780
6790
6800
6820
6840
6860
6880
6900
6402
6502
6702
6732
6742
6772
6782
6792
6802
6822
6842
6862
6882
6902
NEW
6890
6892
Page 6 of 10
SUBJECT:
SUBJECT:
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
375A0-K4452
375A0-K4402
375A0-K4053
375A0-K4003
375A0-K4453
375A0-K4403
TSB #: 23-01-073H-1
6504
6734
6744
6774
6784
6794
6804
6824
6844
6864
6884
6904
6506
6736
6746
6776
6786
6796
6806
6826
6846
6866
6886
6906
6960
6980
7020
7040
7050
7060
7080
7100
7120
6962
6982
7022
7042
7052
7062
7082
7102
7122
6964
6984
7024
7044
7054
7064
7084
7104
7124
6966
6986
7026
7046
7056
7066
7086
7106 7126
6894
6896
7140
7142
7144
7146
Page 7 of 10
SUBJECT:
SUBJECT
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
Manual Mode Password Information:
MENU
PASSWORD
OS EV BMS 375A0-K4052
OS EV BMS 375A0-K4002
OS EV BMS 375A0-K4452
OS EV BMS 375A0-K4402
OS EV BMS 375A0-K4053
OS EV BMS 375A0-K4003
OS EV BMS 375A0-K4453
OS EV BMS 375A0-K4403
5285
0201
2966
2814
9511
3167
3160
0956
C. BATTERY SYSTEM ASSEMBLY (BSA) REPLACE (only when applicable)
C1.
Take STUI photo of the DTC Freeze Frame data with the Information Codes 1-5 visible:
STUI
Take a screenshot of the DTC Freeze
Frame Data showing Information
Codes 1-5 using your particular
tablet’s screenshot save method and
upload to STUI.
EXAMPLE
C2.
Refer to TSB 23-EV-001H for the complete procedures for BSA Replace:
• Techline Approval (from inspection of Freeze Frame Data submitted via STUI)
• PA Approval to allow for BSA Parts Ordering
• Required Tools and Technician Training
• BSA Replacement Procedures
C3.
After BSA is replaced, go to Section B to perform BMS Update if it will apply.
TSB #: 23-01-073H-1
Page 8 of 10
SUBJECT:
SUBJECT:
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
BSA Parts Information:
PART NAME
MODEL
BATTERY SYSTEM
ASSEMBLY (BSA)
Kona
Electric
(OS EV)
PART NUMBER
37501-K4xxxxx*
(*as called out in Parts
Catalog based on VIN)
REMARK
Only as Needed per step A4.
See TSB 23-EV-001H for BSA
replace procedures including
Techline and PA approval required.
NOTE. Choose correct coolant and bolts P/N as indicated by TSB 23-EV-001H.
BSA Replace Warranty Information:
Follow these Instructions to choose the correct Opcode for BSA Replace:
1. Choose the correct TABLE A vs TABLE B:
a. TABLE A – BSA REPLACE + BMS UPDATE
b. TABLE B – BSA REPLACE (No BMS Update)
2. Then match your exact BSA Part Number received to the CAUSAL PART column to determine the OP
CODE and OP TIME:
TABLE A - BSA Replace + BMS Update (NOTE: Must have STUI BMS Update complete photo uploaded)
CAUSAL/
MODEL
REPLACEMENT
MODEL OP CODE
OP NAME
OP TIME NATURE
CAUSE
YEAR
PART
19MY
30D055R2
30D055R8
20MY
30D055RF
30D055RL
30D055RR
Kona
Electric
(OS EV)
30D055RT
30D055RN
37501-K4000AS
DTC (INFO
CODE) CHECK,
BSA
REPLACEMENT
, AND BATTERY
MANAGEMENT
SYSTEM
SOFTWARE
UPDATE
30D055RP
21-23MY
37501-K4001AS
37501-K4051AS
37501-K4051QQH
37501-K4004AS
37501-K4054AS
3.6 M/H
I3A
ZZ3
37501-K4005AS
37501-K4055AS
1. Campaign Claim
30D055R1 for the BMS
Update.
2. Claim additional Normal
Warranty for BSA Replace
– Refer to WebLTS for
opcode.
37501-K4005
37501-K4055
TSB #: 23-01-073H-1
0.4
+
Refer to
WebLTS
for LTS
Page 9 of 10
SUBJECT:
SUBJECT
KONA EV DTC INSPECTION AND BMS UPDATE (SERVICE CAMPAIGN 9A4)
TABLE B - BSA Replace (No BMS Update):
MODEL
MODEL OP CODE
OP NAME
YEAR
19MY
20MY
30D055R3
37501-K4000AS
30D055R9
37501-K4001AS
30D055RG
37501-K4051AS
30D055RM
Kona
Electric
(OS EV)
21-23MY
CAUSAL/
REPLACEMENT
PART
30D055RS
DTC (INFO
CODE) CHECK
AND BSA
REPLACEMENT
OP TIME
NATURE
CAUSE
I3A
ZZ3
37501-K4051QQH
37501-K4004AS
30D055RU
37501-K4054AS
30D055RO
37501-K4005AS
30D055RQ
37501-K4055AS
3.4 M/H
Claim additional Normal
Warranty for BSA Replace –
Refer to WebLTS for opcode.
37501-K4005
37501-K4055
TSB #: 23-01-073H-1
Refer to
WebLTS
for LTS
Page 10 of 10
SUBJECT: