GROUP
ENGINE
ELECTRICAL

Technical Service Bulletin
SUBJECT:

DATE
March, 2020

NUMBER
20-EE-001H
MODEL
Kona Electric (OS EV)
Ioniq Electric (AE EV)

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT PROCEDURES

This TSB revises 19-EE-002. It explains that there are now 2 different types of coolant.
A Tool Acknowledgment Form must be completed and sent in for Techline battery approval.

IMPORTANT


Carefully follow all steps of this TSB. The required special tools and TSB procedures
are very important for safe handling of a large heavy EV battery.



Do not disconnect or remove the 12V or EV battery before the Battery Management
System (BMS) DTC Analysis and Data Analysis screens are collected by the GDS.



The removed EV battery must be carefully handled to avoid physical damage per the
procedures of this TSB.

Description: The following summarizes the procedure for EV battery replacement:
Section
Content
A.
Dealer uses GDS to collect BMS DTC Analysis and BMS Data Analysis.
Dealer calls Techline to establish a case for EV battery replacement.
B.
Both of the following must be sent to Techline Email or Repository:
 EV Battery Replacement Required Special Tools Acknowledgement form.
 BMS Data Analysis screen capture file(s).
C.
Techline approves EV battery replacement case and an EV battery will be
shipped to Dealer. Techline will call back to confirm arrival estimate (ETA).
D.
For first time EV Battery replacement cases, the EV Battery Special Tools will
be shipped to Dealer from Bosch and billed one time to Dealer.
E.
Dealer Technician performs the required online EV Battery Replacement
Training Module before battery arrives. Technician will receive training credit.
F.
Once the required special tools and the replacement EV battery are on hand,
Dealer can remove and replace the EV battery.
G.
Confirm the vehicle can go into Ready mode without warning lights on.
Clear DTC by GDS and make sure no battery related DTC restore.
Perform SOC Calibration by GDS.
H.
Kona and 2020MY+ Ioniq: Fill the P/E coolant reservoir and bleed by GDS.
I.
Dealer test drives the vehicle. Check that it takes a level-1 or level-2 charge.
J.
Secure the removed battery to the shipping box from the replacement battery.
Make sure the battery coolant inlet and outlet nipples are plugged.
Install the battery box cover securely.
K.
Dealer Parts Dept. requests battery return by KBI of the used battery core per
TSB 19-EE-001.
Applicable Vehicles:




Pages
4
5

5
5
5
6-11
11

12
13
13

13

2017MY+ Ioniq Electric (AE EV)
2019MY+ Kona Electric (OS EV)

Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

Warranty Information:
Model

Op Code

Operation

37510R00

HIGH VOLTAGE BATTERY
PACK ASSY

Kona Electric
(OS EV)
37510RQ0

DIAGNOSTIC TOOL
OPERATION

37503R00

HIGH VOLTAGE
BATTERY SYSTEM ASSY

Ioniq Electric
(AE EV)
37510RQ0

DIAGNOSTIC TOOL
OPERATION

Op Time

Causal
Part

Nature
Code

Cause
Code

Refer to
WebLTS

37501XXXXX

I3A

ZZ3

Refer to
WebLTS

37501XXXXX

I3A

ZZ3

EV Battery Required Special Tools Information:


The following special tools are required for the safe, secure, efficient lifting of large heavy EV
battery (~1000lbs). Proper tools are required to avoid damage to the EV battery.



Both tools will be shipped from Bosch to any Dealer at their first EV battery replacement
service as a required special tool.
PART NAME /
(Part Number)

DIAGRAM

REMARK
Shipped from Bosch

Propulsion System
Lift Table

Allows for safe and efficient EV
battery replacement.

(P/N: HMA52200-A)

Engine hoist can fit under it to
raise an EV battery from the table.
Multi-Use air/hydraulic operated
lift rated at 1760 lbs capacity can
lift 21.5 to 70 inches high.
Multiple uses include EV Battery,
Engine/Transaxle, Fuel Tank,
Cradles, Suspensions, and
Chassis systems.

High Voltage Battery
Lifting Fixture

Shipped from Bosch

(P/N: 09375-K4100)

TSB #: 20-EE-001H

Page 2 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

NOTE: The following page must be completed by the Service Manager and sent to Techline
along with the GDS Data Analysis from the Battery BMS System.

EV Battery Replacement Required Special Tools Acknowledgment
EV battery replacement requires a special lift table and a high voltage battery lift fixture to safely
remove and replace the EV battery.
For your first EV battery order, the following essential tools will be shipped to your dealership and
billed through the Bosch Special Service Tool program:



Propulsion System Lift Table (P/N: HMA52200-A)
High Voltage Battery Lifting Fixture (P/N: 09375-K4100)

$4,395.00*
$920.00*

The cost of the tools does NOT include shipping and applicable taxes.
*Price is subject to change.
The undersigned acknowledges receipt of this notice and understands that the dealer will be billed for
these tools upon an initial order of an EV battery.
Dealer Name: ___________________________________
Dealer Code:____________
Dealer Service Manager:
Print Name:_____________________________________________
Signature:______________________________________
VIN:____________________________________________________

If your Dealership already has the tools or an equivalent compatible lift table suitable for EV batteries,
please contact your District Parts & Service Manager to approve and complete this section.
The High Voltage Battery Lifting Fixture must be ordered if Dealer does not have this tool as it is
particular for Hyundai EV batteries.

I certify that the above mentioned dealer has an equivalent lift table suitable for use with Hyundai EV
models.
Manager, District Parts & Service
Print Name:____________________________________
Signature:_____________________________________

TSB #: 20-EE-001H

Page 3 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

Service Procedure:
A-1. Perform the GDS All Fault Search function to review all stored DTC(s).
BMS DTC Search Result:
 Review for any BMS system DTC stored. Verify in the shop manual if any have a
possible cause of EV battery.
 If BMS DTC does not apply to a potential EV battery problem, this TSB does not apply.
A-2. Capture all data from the GDS BMS Data Analysis function as follows:
(Preferred) GDS has an SD card:

GDS does not have an SD card:

Use the GDS Data Capture function that can be
Capture the first page of Data Analysis, either by:
found by scrolling to the right at the top of the GDS  Manual tablet screenshot (press LOCK and
screen:
HOME buttons together).
 Camera shot (turn off flash).




Note the parameter at the bottom of the screen
and manually scroll down until that parameter
shows at the top of the screen.
Capture a manual tablet screenshot or camera
shot of the 2nd page of data.

Selecting the Save button creates a PDF file of the
multiple pages of all the data of the BMS Data
Analysis.



TSB #: 20-EE-001H

Continue the above steps page by page until all
Data Analysis pages are captured & saved.

Page 4 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

B-1. Contact Techline at 1-800-325-6604 to establish a Techline Case to request approval of an EV
battery replacement. Note the Techline case number assigned.
B-2. Upload the following to the Techline Repository or email to: [email protected]:
 BMS Data Analysis Data Capture file(s).
 EV Battery Required Special Tools Acknowledgment form completed by Dealer Service
Manager.
NOTE: Be sure to include Dealer Number, VIN and Techline Case# in the subject line of
each Techline Repository or email submission, so Techline can match to your case.
General Instructions on how to Upload to Techline Repository are found at Technical Training –
Techline Procedures:

C.

Techline reviews the required BMS data and EV Battery Special Tools Acknowledgment Form
to ensure the case qualifies for approval of an EV battery replacement.
Once Techline approves, an EV Battery will be shipped out by Mobis to the Dealer. Shipping
can take 2-7 days depending on location since EV battery can only be shipped by Hazmat
ground transportation. Techline will confirm the estimated time of arrival (ETA).

D.

Required Tools on page-2 will ship out from Bosch (Applicable to Dealer cases of first time EV
battery replacement).

E.