Kia Soul EV: Power Train / Cooling System Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Maintenance / Power Train / Cooling System Repair procedures

Inspection

Radiator hoses

Check radiator hoses for the following

(1)	Improper attachment

(2)

Leaks

(3)

Cracks

(4)

Damage

(5)	Loose connections

(6)

Chafing

(7)	Deterioration

Coolant level

1.	Check the coolant level in the coolant reservoir. Make sure it is between the "F" mark and "L" mark.

2.	If the coolant level in the coolant reservoir is at or below the "L" mark, add coolant to bring it between the "L" and "F" marks, then inspect the cooling system for leaks.

Coolant quality

1.	Remove the radiator cap.

2.	Check if there are any excessive deposits of rust or scale around the radiator cap sub-assembly and radiator filler hole. Also, the coolant should be free of oil. If it is excessively dirty, clean the coolant passage and replace the coolant.

3.	Install the radiator cap.

Coolant Refilling And Bleeding

Never remove the reservoir cap when the high voltage system and electric device radiator are hot. Serious burns may be caused when hot fluid under high pressure escapes from the reservoir.

When pouring electric device coolant, be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off immediately.

1.	Make sure the electric device system and electric device radiator are cool to the touch.

2.	Remove reservoir cap (A).

3.	Remove the under cover. (Refer to Motor & Reduction Gear - "Under Cover")

4.	Loosen the drain plug (A) and drain the coolant.

5.	Tighten the radiator drain plug securely.

6.	After draining engine coolant in the reservoir tank, clean the tank.

Fill the reservoir with water through the reservoir cap and tighten the cap.

To most effectively bleed the air, pour the water slowly and press on the upper/lower radiator hoses.

8.	Connect a GDS and then operate the Electric Water Pump (EWP).

9.	Repeat steps 1 to 8 until the drained water runs clear.

10.

Fill fluid mixture of coolant and water (50%) slowly through the reservoir cap. Push the coolant hoses of the radiator so as to bleed air easily.

•	Use only genuine antifreeze/coolant.

•	For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant concentrations less than 55% may not provide sufficient protection against corrosion or freezing.

•	For best corrosion protection, the coolant concentration must be maintained year-round at 55% minimum. Coolant concentrations less than 55% may not provide • sufficient protection against corrosion or freezing.

•	Do not mix different brands of antifreeze/coolants.

•	Do not use additional rust inhibitors or antirust products; they may not be compatible with the coolant.

11.	Connect a GDS and then operate the Electric Water Pump (EWP).

12.	When the Electric Water Pump (EWP) operates and electric device coolant circulates, refill electric device coolant through the coolant filling bottle.

13.

Bleeding of the electric device cooling system is completed when the operational sound volume of the Electric Water Pump (EWP) gets lower and when no air bubbles can be seen in the coolant filling bottle.

After air bleeding is completed, make sure that electric device coolant in the coolant filling bottle flows without air bubbles during the EWP actuation. If the electric device coolant does not flow or if air bubbles are still visible, repeat steps 10 to 13.

14.

After air bleeding is completed, stop the Electric Water Pump (EWP), add electric device coolant to the “F” level on the electric device reservoir and install the electric device reservoir cap and the electric device reservoir cap.

It takes time to bleed out all the air in the cooling system. Refill coolant when coolant gets cool completely, and then recheck the coolant level in the reservoir tank 2 - 3 days after replacing coolant.

Coolant capacity

Without Heat Pump : Approx. 4.1 ~ 4.2 L (1.08 ~ 1.11 U.S.gal., 4.33 ~ 4.44 U,S,qt., 3.61 ~ 3.70 lmp.qt)

With Heat Pump : Approx. 4.6 ~ 4.7 L (1.22 ~ 1.24 U.S.gal., 4.86 ~ 4.97 U,S,qt., 4.05 ~ 4.14 lmp.qt)

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