Battery, Hybrid Drive: Service and Repair
Removal
WARNING:
This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution .
1. Shut off the high voltage circuit .
2. Remove the trunk trim .
3. Remove the cooling ducts
(1) Remove the installation nuts (A), then remove the inlet cooling duct (B).
(2) Remove the installation nuts (A), then remove the outlet cooling duct (B).
4. Disconnect the BMS extension connector (A).
5. Remove the inverter power cable positive (B) and negative (C) terminals by unscrewing the tightening nuts.
6. Disconnect the cooling fan connector (A).
7. Remove the installation bolts (A), then remove the high voltage battery pack assembly from the vehicle.
Installation
WARNING:
This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution .
1. Installation is reverse of removal.
Inlet cooling duct installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Outlet cooling duct installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Inverter power cable terminal tightening nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
High voltage battery pack assembly installation bolt:
19.6 - 29.4N.m (2.0 - 3.0kgf.m, 14.5 - 21.7lb-ft)
Disassembly
WARNING:
This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution .
1. Remove the installation bolts (A) and nut (B), then remove the high voltage rear cover (C).
2. Remove the BMS ECU.
(1) Disconnect the battery temperature signal connector (A) and control connector (B).
(2) Disconnect the battery voltage signal connectors (C).
(3) Remove the installation nuts (D), then remove the BMS ECU from the high voltage battery pack assembly.
3. Disconnect the PRA connector (A) and the safety plug inter-lock connector (B), then remove the BMS wiring harness.
4. Remove the PRA.
(1) Remove the high voltage protection cover (A).
(2) Remove the high voltage positive (A) and negative (B) power cable terminals by unscrewing the tightening nuts.
(3) Remove the installation nuts (C), then remove the PRA from the high voltage battery pack assembly.
5. Remove the installation nuts (A), then remove the cooling fan.
6. Remove the cooling fan bracket (A).
7. Remove the installation bolts and nuts, then remove the high voltage battery pack cover (B).
8. Disconnect the battery module connectors (A).
9. Remove the battery temperature sensors (B).
Assembly
WARNING:
This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution .
1. Assembly is reverse of disassembly.
High voltage rear cover installation bolt/nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
BMS ECU installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
PRA installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
High voltage power cable terminal tightening nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Cooling fan installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Cooling fan bracket installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
High voltage battery pack cover installation bolt:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
High voltage battery pack cover installation nut:
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Inspection
[Battery Pack Assembly Troubleshooting Chart]
NOTE:
- For SOC check, refer to "SOC Inspection"
- For voltage check, refer to "Battery Voltage Inspection"
- For battery voltage sensing circuit, refer to "Voltage Sensing Circuit Inspection"
- For isolation resistance check, refer to "Isolation Resistance Inspection"
[SOC Level and Follow-up]
[SOC Inspection]
1. Connect the GDS to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Check the SOC in GDS service data.
SOC:20% ~ 90%
[Battery Voltage Inspection]
1. Connect the GDS to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Check the cell and pack voltage in GDS service data.
Cell Voltage:2.5 - 4.2V
Pack Voltage:180 - 300V
[Voltage Sensing Circuit Inspection]
1. Shut off the high voltage circuit .
2. Remove the battery temperature sensor .
3. Check the continuity of the wiring between the harness connectors of the module and BMS ECU.
Specification: below 1Ohms
4. Connect the harness connectors to the BMS ECU.
5. For checking the short circuit to ground, measure resistance between the module harness connectors and chassis ground.
Specification: 1MOhms or higher
[Isolation Resistance Inspection]
1. Connect the GDS to the Data Link Connector (DLC).
2. Turn the ignition switch ON.
3. Check the isolation resistance in GDS service data.
Isolation Resistance:1.0 - 4.0 MOhms
