GROUP

MODEL

ELE

All Applicable
EV/HEV/PHEV Models
w/High-Voltage Battery

NUMBER

DATE

044 (Rev 2, 08/19/2021)

January 2013

TECHNICAL SERVICE BULLETIN
SUBJECT:

HIGH-VOLTAGE BATTERY ORDERING AND
RETURN PROCEDURE

 NOTICE
This bulletin has been revised to include additional information. New/revised sections of this
bulletin are indicated by a black bar in the margin area.
This bulletin outlines the ordering and return procedure for high-voltage Lithium-ion batteries equipped on
EV/hybrid vehicles (hereafter referred to as "high-voltage batteries" or HVBs). Every Kia-approved EV/hybrid
dealership’s Parts and Service departments should follow these procedures to ensure the fastest handling
time and to minimize the possibility of chargebacks.

Limitations on High-Voltage Battery (HVB) Orders
• Non-approved EV/hybrid dealerships cannot order HVBs or be paid by warranty for repairs performed
on hybrid components.
• HVBs cannot be ordered except as direct replacements for damaged or failed HVBs.
• In the case of out-of-warranty or collision-damaged HVBs, evidence of the failure or damage must be
submitted via a Techline case. A core return is required in all cases.
Shipping and Handling Regulations
• Pursuant to federal law, all shipments of HVBs, to or from the dealer, must be shipped by ground
service. Air shipments are not allowed.
• Anyone who receives, packs, ships, or otherwise handles HVBs may need to be hazardous materials
(HazMat) certified, as required by the U.S. Department of Transportation.
• It is the dealership's responsibility to ensure that its team members are appropriately certified and follow
all laws and regulations related to this and other HazMat components on Kia vehicles.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.

Page 2 of 5

HIGH-VOLTAGE BATTERY ORDERING AND RETURN PROCEDURE

SUBJECT:

Ordering Procedure:
The Service department should follow this procedure when requesting a high-voltage battery.

 NOTICE
A Techline case number and Battery Management System (BMS) screenshots are required when
ordering/returning a high-voltage battery.
1.

Use KDS to scan for DTCs.
a) If any HVB DTC (P1B70, P1B74, P1B96, etc.) is found, save screenshots of the DTC search results.
This can be achieved with one (1) or two (2) screenshots.
b) Save the screenshots of each DTC's Freeze-Frame Data. This can be done with two (2) screenshots
per DTC.
c) Select the BMS system and save screenshots of Current Data. (Number of screenshots will vary by
model.) Screenshots are required for core return.

Note: Screenshot examples are provided later in this bulletin in the “KDS Screen Capture Process”.
2.

Create a Techline web case, and include the following items in the initial message:
a) Describe the customer complaint and what portion of the complaint was duplicated or confirmed.
b) Identify (in the case notes) the problem cells from the FFD or BMS Current Data.
c) Upload all screenshots to the case.

3.

A Techline representative will review these details and recommend either HVB replacement or another
action.

4.

If Techline recommends a HVB then they will create/approve a PWA case for DSA-B dealers.
DSA-A dealers will only require a Techline case in order to validate data screenshots for part order and
core return. The case number and BMS screenshots will be required for core returns. Any other
components that are recommended by Techline must be listed on the parts order. (For all repairs,
including non-warranty repairs, evidence of battery failure or damage must be submitted via the
Techline case.)

 NOTICE
HVB packs are shipped from California, and transit times will vary from 1 to 5 business days
from shipment date in the contiguous United States. Transit time of shipments to dealers in
Hawaii or Alaska will require additional time.

 NOTICE
The Battery Management System (BMS) is no longer required to be replaced at the same
time as the High Voltage Battery (HVB) and is only to be replaced when directed by Techline.

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: ELE044 (Rev 2) Multiple Models January 2013

Page 3 of 5

HIGH-VOLTAGE BATTERY ORDERING AND RETURN PROCEDURE

SUBJECT:

Return Procedure:
The Parts department should follow this procedure when receiving a replacement HVB and when returning
the original (core) HVB.

 NOTICE
A Techline case number and Battery Management System (BMS) screenshots are required when
ordering/returning a high-voltage battery.
1.

When the replacement HVB ships, Kia America (KUS) Warranty Department will supply instructions, including
a bill of lading and the emergency response document via email to the dealership Parts department.

2.

When receiving the replacement HVB, inspect the wooden shipping crate of the replacement HVB for
damage. If it was damaged in shipment, be certain to note this on the receiving document, and contact
the Parts Hotline to request a new crate for the HVB.

3.

Care must be taken when unpacking the replacement HVB to not damage the wooden crate. Damage
caused by the dealer will be the dealership's responsibility. Make sure to retain all packaging materials
for reuse.

4.

Package the return HVB in the same manner as the replacement HVB was received.

5.

Follow all federal requirements for preparing the HazMat shipment. KUS cannot legally accept
inappropriately packaged, marked, or mislabeled HazMat shipments. Situations arising from these and
other errors are time-consuming to resolve and may result in fines to the dealer by various government
entities. In addition, if these situations cause financial losses to KUS, KUS may seek reimbursement for
any added processing costs or delays.

Note: See next section for examples of the KDS screen capture process.

KDS Screen Capture Process:
There are two (2) ways to take a screen capture.
1a.

KDS screen:
Take a screenshot using the capture icon (A) in
the upper-right corner of the KDS screen.

A
1b.

Tablet buttons:
Use the tablet screen capture feature by
simultaneously pressing and holding the Home

C

button (B) and the Power button (C).
1c.

Refer to the “KDS - Attaching Files to Techline
Cases” publication under “Diagnostic Tools →
KDS

&

GDS

Information”

on

KGIS

B

for

instructions on how to attach the screenshots to
the Techline case.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: ELE044 (Rev 2) Multiple Models January 2013

Page 4 of 5

HIGH-VOLTAGE BATTERY ORDERING AND RETURN PROCEDURE

SUBJECT:

2.

Drag the scroll bar (D) down to scroll to the next
segment of uncaptured data.
Note: BMS Current Data shown as example
only.

D
 NOTICE
Be sure to take enough screenshots
so that no lines of data are missed.
It is OK to capture a few lines of data

more than once.

First Screenshot
Continue scrolling and taking screenshots as
many times as necessary until all lines of data
have been captured, down to the end of the
scrollable area.
Note: The number of screenshots will vary
depending on model.

 NOTICE
Intermediate

screenshots

are

not

shown in the example at right, but are
still required.

Intermediate Screenshots

Last Screenshot

D

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: ELE044 (Rev 2) Multiple Models January 2013

Page 5 of 5

HIGH-VOLTAGE BATTERY ORDERING AND RETURN PROCEDURE

SUBJECT:

3.

When completed, you should have multiple
screenshot images that comprise ALL of the
data. These image files must be attached to
your

Techline

case

to

ensure

efficient

processing of the case.
Note: In the example shown at right, it took nine
(9) screenshots to capture all of the BMS
Current data for this vehicle.

 NOTICE
Screenshot files should be saved as
JPG or PNG (preferred formats).
Other file types may be unreadable
and may delay processing.
Use this same method for saving screenshots of
DTC search results and each DTC's Freeze
Frame Data.

Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.

TSB: ELE044 (Rev 2) Multiple Models January 2013