GROUP

NUMBER

CAMPAIGN
DATE

Technical Service Bulletin
SUBJECT:

JUNE 2023

23-01-049H
MODEL(S)
KONA Electric (OS EV)
IONIQ Electric (AE EV)

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE AND
COOLANT CHANGE (SERVICE CAMPAIGN T9E)

 IMPORTANT
Dealers must perform this service campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the “Vehicle Information” screen via WEBDCS to identify open campaigns.
Description: This bulletin provides instructions to correct a condition with BSC-1 blue coolant flow
restriction by debris causing abnormal high EWP (electric water pump) speed in certain 2020-21MY
Ioniq Electric (AE EV) and 2019-22 Kona Electric (OS EV) models. Vehicle symptoms may include
"Coolant supplement” or “Refill Inverter Coolant" warning light On. No related DTC are found stored.
Normal inverter coolant reservoir tank level is confirmed. Special tools are required for this campaign
to flush and clean debris from different cooling system circuits. The coolant will be replaced by
updated BSC-2 low conductivity blue coolant.

STUI
As outlined in the Digital Documentation Policy, all claims require VIN and Mileage validation
through VCI connection or photo capture. Additionally, please ensure the repair Part photo
requirement is completed according to the steps in the TSB. All claims submitted that have
incomplete, illegible, or missing documentation are subject to debit.

Applicable Vehicles: Certain:
• 2019 - 2022MY Kona EV (OS EV) vehicles produced from 05/07/2019 to 10/12/2021
• 2020 - 2021MY Ioniq EV (AE EV) vehicles produced from 11/01/2019 - 05/17/2021

i Information
•
•
•

To ensure proper understanding of the service procedure and equipment
connections, it is recommended to view or print this bulletin in color.
When working on the vehicle, ensure to disconnect the high voltage system and wear
protective eye safety goggles to avoid injury from coolant leaks under pressure.
To securely connect the equipment hoses, use existing coolant hose clamps at the
identified locations on the vehicle as the equipment flushes coolant under pressure.

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

SUBJECT:

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE
AND COOLANT CHANGE
`
(SERVICE CAMPAIGN T9E)

Parts Information:
Part Name

COOLANT (BSC-2)

Tools Information:
Tool Name

Coolant Flushing
Equipment Set

Warranty Information:
Op.
Model
Code
Kona
20D140R6
(OS EV)

Figure

Part Number

Remarks.

00232-19113

3 Gallon bottles
per vehicle.

Part Number

KQ253-CV158QQH

Operation

Op.
Time

Qty

Remarks

1

Each dealer will be
shipped one free of
charge

Causal
Part

Nature
Code

Cause
Code

Debris Discharge and
1.9 M/H
Coolant Change
Debris Discharge
20D140R4
and Coolant Change
1.9 M/H 00232E83
ZZ5
(Non Heat Pump vehicle)
19113
Ioniq
(AE EV)
Debris Discharge
20D140R5
and Coolant Change
2.0 M/H
(Heat Pump vehicle)
NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: If a part that is not covered by this campaign is found in need of replacement while
performing this service campaign and the affected part is still under warranty, submit a separate claim
using the same repair order. If the affected part is out of warranty submit a Prior Approval Request for
goodwill consideration prior to performing the work.
NOTE 3: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the parts requested are not returned.
NOTE 4: Op times include VIN, Mileage and Part (if applicable) validation. All claims submitted
that have incomplete, illegible, or missing documentation are subject to debit.
TSB #: 23-01-049H

Page 2 of 27
SUBJECT:

SUBJECT:

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE AND COOLANT CHANGE
(SERVICE CAMPAIGN T9E)

Service Procedure:
NOTE: Video of this service procedure is available at: https://vimeo.com/825335870/9b6a196953

i Information
•
•

To access the appropriate service procedure steps for your specific vehicle, please first review
section A to become familiar with general equipment procedures.
Refer to the below table to locate the applicable sections B or C based on vehicle model
and configuration, along with the specific section steps that apply.

VEHICLE
MODEL

VEHICLE OPTIONS

General Operating Instructions for Coolant
Flush and Filter Equipment:

SECTION

APPLICABLE SECTION
STEPS

A
(begins page 3)

A1-A3

Vehicle mfg.
before 4/8/20*

Kona EV

Non-heat
pump

B1-B14, B17-B24

(Valve type)
Vehicle mfg.
from 4/8/20 or later*

B
(begins page 6)
B1-B14, B15-16, B18-B24

('T' branch pipe type)
C
(begins page
Heat pump
17)
*refer to the VIN Plate on side of door for Mfg (manufacture) date.
Non-heat pump

C1-C16, C19-C24

Ioniq EV

C1-C24

A. General Operating Instructions for Coolant Flush and Filter Equipment
A1.

Air Draining (Coolant Discharge)

NOTICE
When discharging remaining coolant, turn
off the coolant pump and close the inlet
valve to prevent air from flowing back and
interfering with coolant recovery.
•
•
•

Ensure the equipment is set to Air
‘ON’, Pump ‘OFF’, and Inlet Valve
‘OFF’.
Set air pressure to 2 bar for initial
discharge.
If drainage is insufficient, adjust air
pressure up to 3 bar.

TSB #: 23-01-049H

Page 3 of 27
SUBJECT:

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE
AND COOLANT CHANGE
`
(SERVICE CAMPAIGN T9E)

SUBJECT:

A2.

Coolant Cleaning (flushing and filtering of
the vehicle’s coolant circuit)

i Information
When cleaning the cooling circuit using
the equipment, set the equipment as
follows:
•

Pressure 2 bar

•

Air ON

•

Pump ON

•

Inlet valve ON

NOTICE
In order to allow for proper priming of the pump system, ensure the coolant circulation container
always contains at least 8L (half full) of fluid. This can include leftover coolant discharged from
the previous vehicle. Add tap water or distilled water as needed to reach at least half full. Do not
use salty or light water in the container.

TSB #: 23-01-049H

Page 4 of 27
SUBJECT:

SUBJECT:

A3.

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE AND COOLANT CHANGE
(SERVICE CAMPAIGN T9E)

Clean the equipment after each vehicle
service, following these steps:
1. Turn on the water pump first, and then
turn on the air.
2. Visually check the equipment's inlet
end to see if air is coming out.
3. If air is not coming out, use the air
pressure valve to increase the
pressure slightly until air comes out.
4. Set the pressure to 2 bar.

NOTICE
To ensure proper maintenance of the
equipment, follow these steps after
completing a cleaning operation:
1. Use the air gun to blow the filter
from the inside to the outside.
2. Spray air between the filter gaps to
remove any foreign substances
stuck in the filter.
Failure to perform step 2 can result in
decreased flow rate and cleaning
efficiency of the equipment.

TSB #: 23-01-049H

Page 5 of 27
SUBJECT:

SUBJECT:

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE
AND COOLANT CHANGE
`
(SERVICE CAMPAIGN T9E)

Vehicle Service Procedure:
Open the hood of the vehicle and visually inspect the coolant color before proceeding with the steps
outlined in this bulletin.
• This bulletin only applies to vehicles with blue low conductivity coolant.
• If the coolant color of the vehicle being inspected is pink or green, which indicates the use of
general coolant, this bulletin does not apply.
!
•
•

WARNING
When servicing the high voltage system, follow the "Safety Precautions, Cautions, and
Warnings" to prevent electric shock or leakage accidents. Cut off the high voltage first by
following the "High Voltage Cut-off Procedure."
When connecting or disconnecting hoses or operating coolant cleaning equipment, always
wear appropriate eye safety goggles to avoid accidental discharge into your eyes. Serious
injury may occur from electric shock, leakage, or accidental discharge to eyes if the technician
does not follow this warning.

B. Kona (OS) EV - Debris Discharge and Coolant Change
B1.

i Information
The rest of the TSB procedure must be
performed regardless of whether this
EWP check conditions are confirmed or
not.
Initial EWP RPM will be checked at vehicle
start in Ready mode:
• If it is above 2,000 RPM, proceed to
step B2.
• If it is above 2,450 RPM, the phrase
“Coolant supplement” or Inverter
Coolant” warning may appear on the
vehicle cluster.

B2.

Select the Data Analysis (A) icon on the
GDS-M initial screen.

TSB #: 23-01-049H

A

Page 6 of 27
SUBJECT:

SUBJECT:

B3.

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE AND COOLANT CHANGE
(SERVICE CAMPAIGN T9E)

Select the BMS (B) icon and press the ‘OK’
button.

i Information
Example of the Data Analysis Graph at
vehicle start up in Ready mode.
The vehicle has 2 EWP and one of the
EWP briefly increased above 2450 as
seen by the MAX 2460 RPM.

B4.

B

Scroll down to verify that the Battery BTMS
Valve Control Mode (C) is set to Combined
Mode by:
1. If the mode is set to Separated Mode,
perform ignition on/off or key on/off.
2. Change the mode to Combined Mode.
.

i Information

C

The Combined Mode condition is
necessary for adequate cleaning to occur
in the rest of this TSB procedure.

TSB #: 23-01-049H

Page 7 of 27
SUBJECT:

SUBJECT:

B5.

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE
AND COOLANT CHANGE
`
(SERVICE CAMPAIGN T9E)

Remove the underhood service interlock
connector (D).

D

B6.

To drain the coolant, remove the reservoir
tank cap (E) and drain the coolant inside the
tank outside using a javara hose.

i Information

E

F

The reservoir tank has two chambers,
upper and lower. Carefully feel for the
hole between the two halves to insert the
javara hose into the lower chamber.

B7.

Ensure that the reservoir tank degassing
hose valve (F) is closed. If there is no valve,
block the flow path as shown in the example
to the right.
NOTE: The valve is closed when the vehicle
is shipped from the factory.

Example of flow path blocking treatment

Change valve type to CLOSE.

TSB #: 23-01-049H

Page 8 of 27
SUBJECT:

SUBJECT:

B8.

COOLING SYSTEM CIRCUIT DEBRIS DISCHARGE AND COOLANT CHANGE
(SERVICE CAMPAIGN T9E)

Cooling System Circuit: Coolant
Discharge and Air Drain Procedure
To ensure the hoses are securely connected
to the vehicle, follow these instructions:
VEHICLE CONNECTION
EQUIPMENT
POINT
Blue inlet
Coolant tank inlet hose
hose
Red outlet
Coolant tank outlet hose
hose
1. Perform Air Drain for 2 minutes to
discharge and drain the coolant.
(Air ON, Pump OFF, Inlet Valve OFF)