NHTSA ID Number: 10254408
Manufacturer Communication Number: TSB_ELE310_R1
TSB/Document Date: 2024-05-08
Summary
TECHNICAL SERVICE BULLETIN: HIGH-VOLTAGE BATTERY
PACK AND BATTERY MANAGEMENT SYSTEM - 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 provides information regarding the replacement of the High-Voltage Battery Pack Assembly (HV BPA) on some 2015-2017MY SOUL EV (PS EV) produced from July 15, 2014 through June 30, 2017 which were not included in SC267 Safety Recall Campaign. The Battery Management System (BMS) will need to be replaced along with the 'new' HV BPA, when replacing an 'originally' equipped HV BPA on the applicable vehicles. In addition, the 'BMS' system software will also need to be upgraded to complete the repair.
GROUP
MODEL
ELE
2015-2017MY
Soul EV (PS EV)
NUMBER
DATE
310 (Rev 1, 05/07/2024)
October 2023
TECHNICAL SERVICE BULLETIN
HIGH-VOLTAGE BATTERY PACK AND
SUBJECT:
BATTERY MANAGEMENT SYSTEM
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 provides information regarding the replacement of the High-Voltage Battery Pack Assembly (HV
BPA) on some 2015-2017MY SOUL EV (PS EV) produced from July 15, 2014 through June 30, 2017 which were
not included in SC267 Safety Recall Campaign. The Battery Management System (BMS) will need to be
replaced along with the ‘new’ HV BPA, when replacing an ‘originally’ equipped HV BPA on the applicable
vehicles. In addition, the ‘BMS’ system software will also need to be upgraded to complete the repair. Follow
the procedure outlined in this publication to replace the BPA, BMS, and upgrade the BMS software on the
applicable vehicle.
NOTICE
A Technical Service Bulletin is a field fix repair program without customer notification that may be
performed during the warranty period. Any dealer requesting to perform this repair outside the
warranty period will require DPSM approval.
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 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
Flowchart:
Vehicle In
For BPA Replacment
(Not Included
in SC267)
BPA + BMS
Replacement
(TL PWA Process)
Perform
BMS S/W Upgrade
Vehicle Out
IMPORTANT
The new BPA is equipped with a “new” type harness. Techline PWA is required for HV BPA
replacement. Dealer should follow the process included in TSB ELE044 and obtain TL PWA . Claim
submission concerns WILL occur if the dealer does not obtain TL PWA for HV BPA replacement.
Operation Descriptions:
•
BMS Software (BMS S/W)
•
High Voltage Battery Pack Assembly (HV BPA)
•
Battery Management System (BMS)
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
Page 3 of 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
WARNING
Be sure to read and follow the ‘General Safety Information and Caution’, the ‘High Voltage ShutOff Procedures’ and ‘High Voltage Battery Handling Guide’ instructions outlined on KGIS before
doing any work related with the high voltage system. Failure to follow the safety instructions may
result in serious electrical injuries.
BMS ECU Replacement Procedure:
1.
Remove the BPA upper case (A) by referring to
“EV Battery System → High Voltage Battery
System
→
Case
→
Repair
procedures
(Removal)” in the applicable Shop Manual on
KGIS. Refer to KGIS for bolt/nut torque specs.
TECH TIP
Mark the six (6) ‘ground’ bolts and
their location to prevent mixing with
regular bolt prior to reassembly.
Regular Bolt (8)
Ground Bolt (E)
Ground Bolt (E): 6 ea.
Regular Bolt (8): 35 ea.
2.
Replace the BMS ECU by referring to “EV
Battery System → High Voltage Battery
Control
System
→
Battery
Management
System (BMS) ECU → Repair procedures
(Removal)” in the applicable Shop Manual on
KGIS.
3.
Proceed
to
the
‘BPA
and
Voltage
&
Temperature Sensor Wiring Harness (VTSWH)
Replacement Procedure’ on page 10.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
Page 4 of 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
WARNING
Be sure to read and follow the ‘General Safety Information and Caution’, the ‘High Voltage ShutOff Procedures’ and ‘High Voltage Battery Handling Guide’ instructions outlined on KGIS before
doing any work related with the high voltage system. Failure to follow the safety instructions may
result in serious electrical injuries.
BPA Replacement Procedure:
1.
Replace the HV BPA(s) by referring to “EV
Battery System → High Voltage Battery
System → Battery Pack Assembly → Repair
procedures (Removal)” in the applicable Shop
Manual on KGIS.
IMPORTANT
15-17MY
ONLY
new
PN
BPA
is
equipped with a “new” type harness.
(Rev 1) removed swap harness.
Note: SST OK375 E4300 BPA lifting jig and
crane jack (A) are required.
NOTICE
Place the removed BPA on a clean flat
surface. Dealer should follow the
process included in TSB ELE044 and
obtain TL PWA.
Note: The battery pack assembly (BPA)
consists of two (2) (left and right) battery
packs.
2.
Perform the BCM Software Upgrade as
outlined on page 6, in ‘Manual Mode’ only.
3.
Confirm normal vehicle operation.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
Page 5 of 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
ECU Upgrade Procedure:
To correct this condition, the ECU should be reprogrammed using the KDS
download, as described in TSB SST081.
Upgrade Event Name
*728. 15-17MY PS EV BMS Diagnostic Logic Enhancement Touch – 3rd
*Note: Event #728 for 15-17MY PS EV will not appear in the upgrade events list
as it needs to be performed in ‘Manual Mode’ only after BMS replacement.
NOTICE
•
Confirm a fully charged battery (12.3 volts or higher is necessary) is used or utilize a fully
charged jump starter box connected to the battery.
•
Ensure the KDS GDS is sufficiently charged at 60% or higher prior to reflash.
•
All ECU upgrades must be performed with the ignition set to the ‘ON’ position unless otherwise
stated.
•
Damaged VCI II units should not be used and promptly replaced.
•
Be careful not to disconnect the VCI-II connected to the vehicle during the ECU upgrade
procedure.
•
DO NOT start the engine during ECU upgrade.
•
DO NOT turn the ignition key ‘OFF’ or interrupt the power supply during ECU upgrade.
•
When the ECU upgrade is completed, turn the ignition ‘OFF’ and wait 10 seconds before
starting the engine.
•
ONLY use approved ECU upgrade software designated for the correct application.
IMPORTANT
It is recommended to ALWAYS check the Electronic Parts Catalog (EPC) to locate the ECU Part
Number respective to Auto/Manual Mode ROM IDs. DO NOT reference the parts label affixed to
the ECU.
NOTICE
If a ‘Communication Fail’ error notice appears or the upgrade cannot be performed, DO NOT
disconnect the KDS/VCI-II. Contact GIT America Help Desk at (888) 542-4371 or Techline.
Before attempting an ECU upgrade on any Kia model, make sure to first determine whether the
applicable model is equipped with an immobilizer
(IMMO) security system. Failure to follow
proper procedures may cause the PCM to become inoperative after the upgrade and any claims
associated with this repair may be subject to chargeback.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
Page 6 of 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
ROM ID INFORMATION TABLE:
Upgrade Event #728 (15-17MY)
Model
SYSTEM
PS EV
15-17MY*
IMMO
ECU P/No.
37513 E4251
BMS
Yes
37513 E4201
ROM ID
Previous
4604
4804
4704
4904/24
4606
4806
4706
4906/26
New
4944*
4946*
Note: *Perform Event #728 in ‘Manual Mode’ only.
To verify the vehicle is affected, be sure to check the Calibration Identification of the vehicle's ECM ROM ID
and reference the Information Table as necessary.
Refer to TSB SST081 for instructions to upgrade the ‘BMS’ system:
UPGRADE EVENT:
Note: Event #728 for 15-17MY PS EV will not appear
in the upgrade events list as it needs to be performed
in ‘Manual Mode’ only.
Confirm if ‘Heated’ or ‘Non-Heated’ type.
NOTICE
Prior to performing the ECU upgrade, be
sure to check that the KDS is fully charged.
Manual Mode ECU Upgrade Passwords
Menu
Password
PS EV BMS (15~17MY, +electric heater): 37513-E4251
4251
PS EV BMS (15~17MY, -electric heater): 37513-E4201
4201
Note: *Perform Event #728 in ‘Manual Mode’ only.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
Page 7 of 7
HV BATTERY PACK AND BATTERY MANAGEMENT SYSTEM
SUBJECT:
AFFECTED VEHICLE RANGE:
Model
Production Date Range
15-17MY Soul EV (PS EV)
July 15, 2014 to June 30, 2017
REQUIRED TOOL:
Tool Name
Part Number
BPA Lifting Jig
OK375 E4300
Figure
Comments
To be used along
with an engine
crane/hoist.
REQUIRED PART:
Part Name
Part Number
Figure
Battery Management
37513 E4201FFF
Qty.
Comment
Non-Heated
1
System (BMS)
(15-17MY only)
Battery Pack
Assembly (BPA)*
37513 E4251FFF
Heated
37510 E4203R*
Non-heated
1
(15-17MY only are equipped
37510 E4253R*
with an original/old VTSWH)
Heated
*Note: The replacement part numbers will require a VIN entry for parts ordering. DO NOT order these parts
for stocking purposes, related to this Campaign. Supply is very limited. Until supply stabilizes, please confirm
part availability before scheduling customers. New BPA PNs now have the ‘new’ type wiring harness.
IMPORTANT: The parts listed below DO NOT required replacement unless damaged or lost during removal.
Case Gasket
37528 E4000FFF
(15-19MY)
N/A
Replace only
1
if damaged
WARRANTY INFORMATION:
N Code: W11 C Code: ZZ4
MY
Claim
Type
Causal P/N
Qty.
Repair
Labor Op
Op
Replacement
Description
Code
Time
P/N
Qty.
37510 E4203R
1517MY
W
37510
0
E4000
BPA+BMS
or
Replacement +
37510 E4253R
BMS S/W Upgrade
Rev 1: (No VTSWH Swap
Required with ‘new’ BPA)
37510F06
3.0
M/H
1
37513 E4201FFF
or
37513 E4251FFF
1
37528 E4000FFF*
1
Note: Techline PWA is required for HV BPA replacement. Dealer should follow the process included in
TSB ELE044 and obtain TL PWA . Claim submission concerns WILL occur if the dealer does not obtain
TL PWA for HV BPA replacement.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: ELE310 (Rev 1) Soul EV (PS EV) October 2023
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TSB/Document ID: TSB_ELE310_R1
Replacement Service Bulletin Number:
MFR Communication Date: 2024-05-08
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System: ELE
MFR Component Subsystem:
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