Kia Soul EV: High Voltage Battery System / Power Relay Assembly (PRA) Repair procedures

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

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 assembly. (Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")

Loosen 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)

After loosening the mounting bolt, remove the high voltage battery pack 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.	Remove the high voltage power cable cover (A) and the inverter busbar cover (B).

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)

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)

Remove the inverter busbar (A).

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

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

9.	Disconnect the power relay assembly connector (A).

10.

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

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

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.

1.	Install the power relay assembly in the reverse order of removal.

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