Kia Soul EV: High Voltage Battery System / Battery Pack Assembly Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / EV Battery System / High Voltage Battery System / Battery Pack Assembly Repair procedures

Inspection
   
When removing the battery pack assembly to inspect the battery system, it can be connected to vehicle by using the SST 0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery system assembly, check if the battery is OK by using the SST.
[SOC Inspection ]
1.
Turn the ignition OFF.
2.
Connect the GDS to DLC.
3.
Turn the ignition ON.
4.
Check the SOC in the GDS service data.

SOC: 5% ~ 95%

[Battery Voltage Inspection]
1.
Turn the ignition OFF.
2.
Connect the GDS to DLC.
3.
Turn the ignition ON.
4.
Check the Cell Voltage and the Pack Voltage in the GDS service data.

Cell Voltage: 2.5V ~ 4.3V
Pack Voltage: 240V ~ 413V
Voltage gap between cells : Less than 40 mV

[Insulation Resistance Inspection (By using the GDS)]
1.
Turn the ignition switch OFF.
2.
Connect the GDS to DLC.
3.
Turn the ignition switch ON.
4.
Inspect the insulation resistance in the GDS service data.

Specified value: 300K? ~ 1000K?

[Insulation Resistance Inspection (By using the Mega Ohm Tester)]
1.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shout-off Procedure")
2.
Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
   
For precise measuring, connect the negative (-) terminal to the parts not painted.

3.
After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
(1)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2)
Check the resistance.

Specified value : More than 2M? (20°C)

4.
After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
(1)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2)
Check the resistance.

Specified value : More than 2M? (20°C)

Removal
   
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1.
Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")
2.
Remove the safety plug cable assembly bracket mounting bolt (A).

Safety plug cable assembly bracket mounting bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

3.
After loosening the mounting bolt, remove the upper case (A).

High voltage battery pack upper case mounting bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

4.
Disconnect the RAD wiring connector (A).
[Right]

[Back]

[Left]

5.
After loosening the mounting nut, remove the battery module outlet duct (A).

Battery module outlet duct mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

6.
After loosening the mounting bolt, remove the bracke (A).

Battery rear mounting bracket mounting bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

7.
Remove the high voltage power cable cover (A).

8.
After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B)

High voltage positive (+) power cable mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

9.
After loosening the mounting nut (A), remove the high voltage negative (-) power cable (B).

High voltage negative (-) power cable mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

10.
Remove the inverter busbar cover (A).

11.
Remove the inverter busbar (A).

Inverter busbar mounting bolt/nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

12.
Disconnect the high voltage battery heater system control positive (+) power and the ground connector (A).
[With high voltage battery heater system]

13.
Dsiconnect the power relay assembly connector (A).

14.
After loosening the mounting nut, remove the power relay assembly (A).

Power relay assembly mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

15.
Disconnect the BMS ECU connector (A).

16.
After loosening the mounting nut, remove the BMS ECU (A).

-BMS ECU mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

17.
Disconnect the safety plug interlock connector (A).

18.
After loosening the mounting nut (A), remove the safety plug cable assembly (B).

Safety plug cable assembly mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

19.
After loosening the ground bolt (A), remove the BMS extension wiring (B).

Ground bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

20.
Remove the high voltage battery pack assembly.
(1)
Remove the high voltage battery pack assembly mounting bolt.

High voltage battery pack assembly mounting bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(2)
Install the SST No. 0K375-E4300 (A) in battery pack assembly as shown in the image below.
   
Be sure to screw the eye bolts to the holes firmly not to allow the bolts to be loosened while lifting the battery pack assembly using a crane jack.

(3)
Install the SST No. OK375-E4300 (A) to crane jack.

(4)
Install the SST No. OK375-E4300 & crane jack (A).
   
Make sure that the hanger hooks and the eye bolts align.
Adjust the hanger main frame to fit the size of the battery pack assembly.

(5)
Remove the high voltage battery pack assembly (A).

   
Make sure that the battery pack assembly is balanced.
   
The battery pack assembly is divided into LH / RH battery pack so be sure to remove the battery one by one. The order of removal is not important.

21.
After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack assembly.
[LH]

[RH]

Installation
   
Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
   
When installing the RAD harness, be sure to check if the connector is installed on the correct position.
[If not correct]
1. Failure of precharging
2. RAD malfunction (misrecognize that the high voltage battery is swollen)
[Main inspection items]
1. Check if the RAD switch faces down

2. Be careful not to reverse battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin) when assembling.

3. Be careful not to reverse battery No. 8 module RAD connector ( 2 pins) and the BMS extension connector (1 pin) when assembling.

1.
Install the high voltage battery pack assembly in the reverse order of removal.
Battery Pack Assembly Components and Components Location
Components Without High Voltage Heater System 1. High Voltage Battery Pack Assembly2. Runaway Arresting Device (RAD)3. Busbar4. Inlet Temperature Sensor5. Voltage & Temperature Sensor Wiri ...

Power Relay Assembly (PRA) Description and Operation
Description Power relay assembly (PRA) is installed in the high voltage battery system assembly and it consists of main relays which control the high voltage, pre-charge relay, pre-charge resis ...

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