Kia Soul EV: High Voltage Battery System / Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / EV Battery System / High Voltage Battery System / 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.
Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
2.
Shut off the high voltage. ("Refer to "High Voltage Shut-off Procedure")
3.
Lift the vehicle.
4.
After loosening the nut, remove the high voltage battery front under cover (A).

5.
After loosening the nut, remove the high voltage rear under cover (A).

6.
Disconnect the BMS connector (A).

7.
Disconnect the high voltage cable (A).

8.
Disconnect the ground cable (B) by loosening the mounting bolt (A).

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

9.
Support the high voltage battery pack assembly with the jack (A).
   
Securely support the battery pack assembly with a jack to prevent any accidents.
Confirm that high voltage cable & connectors are completely removed before removing the battery pack assembly.
Place rubber on the jack to protect the lower part of the battery pack and the stud bolts used to tighten the under cover.

10.
Loosen the high voltage battery system assembly mounting bolt (A).

High voltage battery system assembly mounting bolt: 54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)

[Front]

[Right]

[Left]

[Back]

11.
Remove the high voltage battery system assembly (A) from the vehicle.

Disassembly
   
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 ground cable (B) by loosening the mounting bolt (A).
[Right]

[Left]

3.
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)

4.
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)

5.
Remove the waterproof gasket (A).

6.
Disconnect the RAD wiring connector (A).
[Right]

[Back]

[Left]

7.
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)

8.
After loosening the mounting bolt, remove the bracket (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)

9.
Remove the high voltage power cable cover (A).

10.
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)

11.
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)

12.
Remove the inverter busbar cover (A).

13.
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)

14.
Disconnect the high voltage battery heater system control positive (+) power and the ground connetor (A). [With high voltage battery heater system]

15.
Dsiconnect the power relay assembly connector (A).

16.
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)

17.
Disconnect the BMS ECU connector (A).

18.
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)

19.
Disconnect the safety plug interlock connector (A).

20.
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)

21.
Loosen the BMS extension wiring mounting bolt (A).

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

22.
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)

23.
After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).

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

24.
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 aligns.
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.

25.
After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack assembly.
[LH]

[RH]

A/S unit
BMS ECU
Refer to High Voltage Battery Control System - "BMS ECU"

High Voltage Battery Pack Assembly
Refer to High Voltage Battery System - "Battery Pack Assembly"

Power Relay Assembly (PRA)
Refer to High Voltage Battery System - "Power Relay"

Inverter Busbar
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
2.
Remove the inverter busbar cover (A).

3.
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)

BMS Wiring Harness
1.
Remove the BMS ECU
(Refer to High Voltage Battery Control System - "BMS ECU")
2.
Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly")
3.
Loosen the BMS extension wiring mounting bolt (A).

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

4.
After loosening the mounting 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)

Safety Plug Cable
Refer to High Voltage Battery Control System - Safety Plug - "Safety Plug Cable"

Front Case Left Panel
1.
Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly")
2.
Remove the front case left panel.

Safety Plug Bracket
1.
Shut off the high voltage.
(Refer to High Voltage Battery Control System - "High Voltage Shut-off Procedure")
2.
After loosening the mounting bolt (A), remove the safety plug bracket (B).

High Voltage Connector Assembly
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2.
After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).

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

Battery Rear Mounting Bracket
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2.
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)

3.
After loosening the mounting bolt (A), remove the bracket (B).

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

Watertight Rainforcement Bracket
1.
Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedures - "Removal")
2.
After loosening the mounting bolt & nut, remove the watertight rainforcement bracket (A).

High Voltage Battery System Rear Mounting Bracket
1.
Lift the vehicle.
2.
Loosen the high voltage battery system rear mounting bracket bolt (A).

High voltage battery system rear mounting bracket bolt : 54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)

3.
Loosen the rear mounting bolt (A).

High voltage battery system rear mounting bracket bolt : 54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)

4.
Remove the high voltage battery system rear mounting bracket (A).

Battery Voltage & Temperature Sensor Wiring Harness
1.
Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "High Voltage Battery Pack Assembly")
2.
After loosening the harness mounting screw, remove the voltage & temperature wiring harness (A) from the high voltage battery pack assembly.
[LH]

[RH]

High Voltage Positive (+) Power Cable
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2.
Disconnect the high voltage power cable cover (A).

3.
After loosening the mounting nut, remove the high voltage positive (+) power cable (A).

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)

High Voltage Negative (-) Power Cable
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2.
Disconnect the high voltage power cable cover (A).

3.
After loosening the mounting nut, remove the high voltage negative(-) power cable (A).

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)

Battery Module Outlet Duct
1.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - Case - "Upper Case")
2.
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)

Safety Plug
Refer to High Voltage Battery Control System - "Safety Plug"

High Voltage Battery Pack Lower Case
Refer to High Voltage Battery System - Case - "Lower Case"

High Voltage Battery Pack Upper Case
Refer to High Voltage Battery System - Case - "Upper Case"

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.
Inspection
Inspection     • Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failur ...

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