Perform the EV Battery Replacement Online Training Module on the “Hyundai Technical
Training” Learning Portal (if a Hyundai only Dealer) or, on the “Learning Portal” (if a dual
Hyundai and Genesis Dealer). The course will provide Technician training credit.
Hyundai Dealer:

TSB #: 20-EE-001H

Dual Hyundai and Genesis Dealer:

Page 5 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

F-1. After the EV battery and special tools are on hand, remove the EV battery from the vehicle per
the specific shop manual instructions for each model and place the battery on the lift table.
Begin by removing the service plug from the battery and wait 5+ minutes for inverter discharge.
Refer to the Battery Removal Tips on the next page.
Kona EV: High Voltage Battery System – Repair Procedures:

Ioniq EV: High Voltage Battery System – Repair Procedures:

TSB #: 20-EE-001H

Page 6 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

F-2. Battery Removal Tips:


You must use the SST P/N: HMA52200-A
Propulsion System Lift Table as shown in
the Required Tools section.
Place a piece of cardboard on the table top
of 1/8 inch thickness minimum.

All Kona EV and 2020MY+ Ioniq only:


When disconnecting the coolant hoses from
the Kona EV battery, clamp the hoses
carefully from the vehicle side to avoid
losing coolant from the reservoir.



Catch the coolant that drains and discard it.



Attach a short spare coolant hose (from
your shop supply) to one side of the pair of
coolant nipples from the battery.
Blow out all the coolant from the battery
from the other coolant nipple using shop air
as shown.



Loop and attach the spare coolant hose to
both coolant nipples from the battery.
NOTE: Clamp the hose at both nipples to
prevent coolant from draining during
handling and shipping of the battery.

TSB #: 20-EE-001H

Page 7 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

F-3. Exchanging Battery from the Vehicle with the Service Battery:
a)

When the EV battery is received in the shipping box use a fork lift (with extenders if available) or
pallet jack to carefully lift and transport the battery to the work site.
NOTE: There are 2 different styles of boxes, each is opened in different ways:
OEM Box:


OEM EV battery box will have a top cover
that is secured by nails or screws.



Nails will need to be pried up or screws
removed to be able to remove the cover.

Refurbished EV Battery Box:


Refurbished EV battery box has a full cover
assembly with integrated side panels.



It includes clips at the bottom to secure the
cover to the bottom crate containing the
battery. These clips will need to be
removed and saved for attaching back.



Flip up the full cover assembly as shown.



Remove the straps securing the battery in
place.

TSB #: 20-EE-001H

Page 8 of 14

SUBJECT:

b)

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

Assemble the High Voltage Battery Lifting
Fixture SST P/N: 09375-K4100 to the EV
battery as per the instructions provided with
the kit depending on model and type of battery.
NOTE: For Kona EV battery, use the (OS EV
PACK Extended Type) instructions. Do not
follow instructions for the Economical Pack.

The following instructions depend on whether a Fork Lift (preferred) or an Engine Hoist is used:
Fork Lift Instructions:

Engine Hoist Instructions:

c)

Use a fork lift with chains and the Lifting
Use a pallet jack on one side to raise the crate
Fixture Kit to raise up the replacement battery: to make it possible to fit an Engine Hoist in
place on the other side to lift up the battery.

d)

Move the replacement EV battery and carefully
place it on the shop floor as a temporary
resting point.
Remove the Lifting Fixture Kit from the battery.

TSB #: 20-EE-001H

Move the replacement battery with the Engine
Hoist to a spare shop lift or other suitable
raised surface that would allow for the Engine
Hoist to roll under to receive the battery. This
will be a temporary resting point.
Remove the Lifting Fixture Kit from the battery.

Page 9 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

Fork Lift Instructions:

Engine Hoist Instructions:

e)

After the EV battery was removed from the
vehicle, install the Lifting Fixture Kit to be able
to raise it from the Lift Table by Fork Lift.

After the EV battery was removed from the
vehicle, install the Lifting Fixture Kit to be able
to raise it from the Lift Table by Engine Hoist.

f)

Move the EV battery from the vehicle to the
Move the EV battery from the vehicle to the
shipping crate and carefully lower it in place so shipping crate and carefully lower it in place so
it is centered on the crate.
it is centered on the crate.

g)

Transfer the Lifting Fixture Kit back to install on
the replacement battery.
Raise the replacement battery from its
temporary resting point and place it onto the
Lift Table.

TSB #: 20-EE-001H

Transfer the Lifting Fixture Kit back to install on
the replacement battery.
Raise the replacement battery from its
temporary resting point (of step-d) and place it
onto the Lift Table.

Page 10 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

F-3. Install the replacement battery to the vehicle in
reverse of the shop manual removal
instructions.

G-1. After installation is complete, check that the
vehicle will go into READY mode and there are
no warning lights on.
NOTE: (For Kona only). The Powertrain
Electronics (P/E) coolant has not been filled
yet, so a low cooling warning light might occur,
but that will be taken care of at step H.

G-2. Check All Fault Search DTC and clear DTC.
Make sure no BMS battery related DTC
restores.

See example of a BMS screen with no DTC,
confirming that proper battery installation had
occurred.

G-3. Perform the SOC Calibration found in the S/W
Management, EV Battery System section of
GDS.

TSB #: 20-EE-001H

Page 11 of 14

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

SUBJECT:

Section H applies to all Kona EV and 2020+ Ioniq EV which has a battery with coolant:

NOTICE
There are 2 types of Coolant as identified by color. The correct coolant must be identified and
you cannot mix coolant between the 2 types. The blue coolant is a special low conductivity
coolant and is not to be mixed with water, unlike the regular green coolant.

H-1. Fill the P/E cooling system reservoir to the
MAX full mark with the following depending on
the type of coolant found in the vehicle:
Coolant
Part
Comment
Color
Number
Green
regular
50/50 mix
coolant
with water
Blue

TSB #: 20-EE-001H

Use only
Hyundai P/N
00232-19091

Do not mix
with water

Page 12 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

H-2. Using GDS with Ignition ON, perform the P/E
cooling system air bleeding procedure.
This will take about 30 minutes.
As the air is purged, recheck and add coolant
as necessary.

I-1. Perform a test drive for at least 2-3 miles and
make sure vehicle is OK.

TSB #: 20-EE-001H

Page 13 of 14

SUBJECT:

ELECTRIC VEHICLE (EV) BATTERY REPLACEMENT SERVICE PROCEDURES

I-2. Confirm the battery will take charge from a
Level-2 charger (faster) or the Level-1 charger
that came with the vehicle.
Recommended to keep the vehicle on a Level2 charger until customer picks up the vehicle,
so it can be delivered at the highest possible
charge.
J-1. Secure the used EV battery tightly in place with
the provided straps onto the crate to minimize
any movement during shipping.

J-2. For Kona EV only, ensure there will be no
coolant leaking out of the battery onto the
shipping crate.
Use a spare coolant hose from your shop to
loop and clamp over the 2 coolant nipples.

J-3. Place the cover on the battery shipping box
and make sure it is secured firmly in place to
prevent the cover from dislodging during the
return shipping. Secure any clips if they came
with the box originally.
K.

Dealer Parts Dept. must follow TSB
19-EE-001H-1 to schedule pickup by KBI of the
used battery core as soon as possible. KBI
will provide specific instructions.

TSB #: 20-EE-001H

Page 14 of 14