NHTSA ID Number: 11006114
Manufacturer Communication Number: 24-EV-005H
TSB/Document Date: 2024-08-07
Summary
Certain 2020-21MY IONIQ Electric (AE EV) vehicles may experience a condition of EV warning light ON with DTC P1AA600 – P1AB000. If any of the DTC’s listed below are found, the Battery System Assembly (BSA) will be replaced, and the Battery Management System (BMS) software may need to be updated.
GROUP
NUMBER
EV SYSTEMS
24-EV-005H
DATE
Technical Service Bulletin
MODEL(S)
IONIQ ELECTRIC
(AE EV)
JULY 2024
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
Description: Certain 2020-21MY IONIQ Electric (AE EV) vehicles may experience a condition of EV
warning light ON with DTC P1AA600 – P1AB000. If any of the DTC’s listed below are found, the Battery
System Assembly (BSA) will be replaced, and the Battery Management System (BMS) software may
need to be updated.
List of Applicable DTC(s): P1AA600, P1AA700, P1AA800, P1AA900, P1AAA00, P1AAB00,
P1AAC00, P1AAD00, P1AAE00, P1AAF00, and P1AB000.
Applicable Vehicles:
• 2020 – 2021MY IONIQ Electric (AE EV) produced from 10/17/2019 – 05/17/2021.
Parts Information:
Part Number
Year
Description
Quantity
Remarks
20-21MY
Battery System
Assembly
(BSA)
1
Use Web Parts
Catalog to
determine
original BSA
Part Number
Vehicles
manufactured
05/07/2019
or later.
Blue Coolant
BSC-2
(Low-Conductivity)
3 Bottles
(1 Gallon Each)
Do not mix
with water
37501-G7600AS
37501-G7601AS
00232-19113
Figure
NOTE 1: Battery System Assembly (BSA) replacement must have Warranty PA approval prior to
ordering and replacing the BSA. Upload a picture of the OLD High Voltage Battery
Label and a
screenshot of the DTC to STUI prior to contacting PA.
NOTE 2: Be sure that Campaign T9E (if applicable) has been performed prior to BSA replacement to
prevent cooling system debris contamination.
GDS Information:
System
Event#
Description
BMS
1018
AE EV PE - IMPROVED MONITORING LOGIC APPLICATION
(*or use a later available event as listed in the GDS for ECM Upgrade screen if one is available.)
NOTICE
To avoid any potential damage to IONIQ vehicles, IONIQ repairs can only be performed at IONIQ
certified dealers.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
SST Information:
Tool Name
High Voltage
Battery Lifting
Fixture
High Voltage
Battery Pack
Transport
Hanger
Tool #
Figure
Remarks
09375-K4100
This tool has been
shipped to all Hyundai
dealers to lift and
transport the
High Voltage BSA.
09375-G7100
This additional tool is
needed to complement
the above
lifting fixture to fit
20MY and later
IONIQ AE EV vehicles.
This tool can be used to
lift and transport the
High Voltage BSA.
Bosch
Battery Lift
Fixture Sling Kit
09375-K4100-02
The contents of this tool
can be used to lift the
100kW BSA without
requiring an additional
fixture.
NOTE 1: SST 09375-K4100 and 09375-G7100 must be used together to lift and transport the 100kW
BSA on the 20-21MY IONIQ AE EV.
NOTE 2: SST 09375-G7100 and 09375-K4100-02 are available on a loan basis for Hyundai Dealers.
Limited quantities available for loan so please contact [email protected] for details.
NOTE 3: Additional SST Tools can be ordered through Bosch at 1-866-539-4248 or hyundai.servicesolutions.com.
NOTE 4: If further assistance is required, please contact [email protected].
Warranty Information:
Model
IONIQ
Electric
(AE EV)
Op. Code
Operation
37501F08
DTC CHECK, BSA
REPLACEMENT, AND
BMS S/W UPDATE
Op. Time
Causal Part
Nature
Code
Cause
Code
4.6M/H
37501-G7****
(refer to parts catalog
for full part number
according to the VIN)
W11
ZZ3
NOTE 1: Normal warranty applies.
NOTE 2: Submit claim on Claim Entry Screen as “Warranty” type.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and Repair
validation photos as outlined in the Digital Documentation Policy.
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 5: If a part is found in need of replacement while performing this TSB 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.
TSB #: 24-EV-005H
Page 2 of 8
SUBJECT:
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
Inspection Procedure Overview:
➢ If the related DTC(s) exists, replace the BSA following the procedures on
TSB 23-EV-001H (or latest version) and perform BMS Event #1018 software update
(if applicable).
➢ If any other DTC(s) exists, this TSB does not apply. Follow the DTC Guide to
appropriately diagnose and repair the vehicle.
TSB #: 24-EV-005H
Page 3 of 8
SUBJECT:
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
A) DTC Check
1.
Using the GDS, perform a Fault Code Search
under the BMS System.
2.
Check for any of the related DTCs to the right.
➢ No:
None of the DTCs listed to the right are
found.
o This TSB does not apply. Follow
the DTC Guide to appropriately
diagnose and repair the vehicle.
➢ Yes:
If related DTC is found, follow the
service procedure in Section B (BSA
Replacement) and Section C (BMS
Software Update).
!
WARNING
•
When working on the high voltage system, make sure that you are familiar and comply
with the "Safety Precautions, Cautions and Warnings." If you do not comply with the
instructions, serious accidents due to electric shock or leakage may occur.
•
When working on the high voltage system, make sure to cut off the high voltage first
according to the "High Voltage Cut-off Procedure." If you do not comply with the
instructions, serious accidents due to electric shock or leakage may occur.
i
Information
5
•
•
•
Refer to TSB 23-EV-001H (or latest version) for EV Battery Approval, Receiving, and
Replacement Procedures.
Dealer Tools and Tech Training requirements per TSB 23-EV-001H (or latest version)
must be satisfied for PA approval.
Parts CSP order of a replacement BSA requires Warranty PA approval and VIN.
TSB #: 24-EV-005H
Page 4 of 8
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
B) Battery System Assembly (BSA) Replacement
1.
Refer to TSB 23-EV-001H for the complete
instructions for EV Battery Approval, Handling,
and Replacement Procedures.
NOTICE
Battery System Assembly (BSA) can only
be ordered and replaced once Warranty
PA approval has been secured.
2.
Replace the Battery System Assembly (BSA).
Refer to Shop Manual:
Battery Control System > High Voltage
Battery System > Repair Procedures
A
3.
STUI
EXAMPLE
Using STUI, take a photo of the NEW
Battery System Assembly (BSA) label
with the last 6 digits of the VIN and the
date of repair on a piece of paper.
Upload the photo to STUI.
4.
Reinstall in the reverse order of removal.
TSB #: 24-EV-005H
Page 5 of 8
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
5.
Refill the motor cooling system with coolant
and complete the bleeding procedure.
Refer to Shop Manual:
Battery Control System > High Voltage
Battery System > Cooling System > Electric
& High Voltage Battery Cooling System >
Coolant > Repair Procedures
NOTICE
Be sure to use the updated Blue Coolant
(BSC-2) when re-filling and bleeding the
cooling system.
6.
Go to Section C after the BSA replacement to
check and perform the BMS software update
(if applicable).
TSB #: 24-EV-005H
Page 6 of 8
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
C) BMS Software Update
NOTICE
You must initially perform the GDS ECU Update in Auto Mode.
• If the ECU Update starts but then fails in Auto Mode, perform the update in Manual Mode to
recover.
NOTICE
GDS Vehicle Battery Low Voltage Warning:
If voltage is below 12 volts as per the below GDS warning, then select Back and attach a battery
charger to ensure an adequate battery state of charge for reliable update results. Turn ignition
back on, and then retry the ECU update again.
i Information
Before performing the AUTO software updates, write down or take a picture of the current
ROM ID in case MANUAL update is required. This information will be used to select the
correct MANUAL passcode/event.
1.
Perform the BMS Update in Auto Mode.
Use the Auto Mode ID check to verify the ECU
ROM ID before updating the software.
i Information
Refer to TSB 24-GI-012H for additional
tablet-based GDS-Smart ECU update
information.
NOTICE
BMS Upgrade Event # 1018 may have
been installed during Service Campaign
TBF, reference the current ROM ID to the
ROM ID information table on Page 8 to
determine if the update is necessary.
TSB #: 24-EV-005H
Page 7 of 8
SUBJECT:
IONIQ EV DTC INSPECTION AND BSA REPLACEMENT
SUBJECT:
2.
STUI
Take a screenshot of the BMS Update
Complete screen using your particular
tablet’s screenshot save method and
upload to STUI.
If there is not a BMS Upgrade available,
please verify Event # 1018 has been
installed, and provide a screenshot of
the current ROM ID and upload to STUI.
3.
After the ECU Upgrade process shows 100%
complete, cycle the ignition key to OFF for at
least 10 seconds to reset the control unit.
4.
Perform an All-Systems Fault Code search
and erase the history of the DTC that had
incidentally occurred from the ECU update.
5.
Start the vehicle to confirm proper operation of
the vehicle.
6.
Service procedure is now completed.
ROM ID Information Table: Event # 1018 (BMS)
ROM ID
BMS
MY
Part Number
OLD
Model
Ioniq Electric
(AE EV)
20-21MY
375A0-G7602
5402
5502
5802
5822
5842
Manual Mode Password: Event #1018
ECM Menu
NEW
6002
Password
7402
AE EV PE BMS 375A0-G7602
TSB #: 24-EV-005H
Page 8 of 8
SUBJECT:
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TSB/Document ID: 24-EV-005H
Replacement Service Bulletin Number:
MFR Communication Date: 2024-07-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL/PROPULSION SYSTEM
MFR Component System:
MFR Component Subsystem:
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