Kia Soul EV Owner's Manual Quiz
Electric Vehicle Battery System

Battery Pack Assembly Repair Procedures

In this manual: Electric Vehicle Battery System
General Information — 17Maintenance — 17Drive Shaft and Axle — 15Suspension System — 36Steering — 24Restraints — 48Brake System — 37Body (Interior and Exterior) — 207Body Electrical System — 203Heating, Ventilation, and Air Conditioning — 80Electric Vehicle Battery System — 115
37steps
~222min
4/5difficulty
0102030405011.89N·mlb·ft
Tightening torque found on this page
Done 0 of 37

Inspection
When removing the battery assembly for inspection, the battery system can be connected to the vehicle using SST 0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery assembly, check the battery system operation using the SST.

[SOC Inspection]

  1. Turn the ignition OFF.
  2. Connect GDS to the DLC.
  3. Turn the ignition on.
  4. Check the SOC in the GDS service data.

    SOC: 5% ~ 95%

[Battery Voltage Inspection]

  1. Turn the ignition OFF.
  2. Connect GDS to the DLC.
  3. Turn the ignition on.
  4. Check Cell Voltage and Pack Voltage in GDS Data. Cell voltage: 2.5 V ~ 4.3 V. Pack voltage: 240 V ~ 413 V. Cell voltage deviation: Less than 40 mV.

[Insulation Resistance Check (Using GDS)]

  1. Turn the ignition off.
  2. Connect GDS to the DLC.
  3. Turn the ignition on.
  4. Check the insulation resistance in the GDS service data.

    Specified value: 300 kΩ to 1000 kΩ

[Insulation Resistance Check (Using Megohmmeter)]

  1. Disconnect high voltage. (Refer to High Voltage Battery Management System - "High Voltage Disconnection Procedure")
  2. Connect the negative (-) lead of the megohmmeter (A) to the vehicle body ground.
    For accurate measurement, connect the negative (-) lead to unpainted parts.
  3. After connecting the positive (+) lead to the positive (+) battery terminal, measure the resistance as follows.
    1. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
    2. Check the resistance.

      Specified value: more than 2 MΩ (20°C)

  4. After connecting the positive (+) lead to the negative (-) battery terminal, measure the resistance as follows.
    1. Apply 500 V with the megohmmeter, then wait approximately 1 minute to measure a stable resistance value.
    2. Check the resistance.

    Specified value: more than 2 MΩ (20°C)

Removal
  • Be sure to read and observe the "General Safety Information and Caution" before performing any work on the high voltage system. Failure to follow the safety instructions may result in serious electrical injury.
  • Before performing any work, be sure to disconnect high voltage related to the high voltage system (refer to "High Voltage Disconnection Procedure"). Failure to follow safety instructions may result in serious electric shock.
  1. Remove the high voltage battery pack. (Refer to High Voltage Battery System - Battery Pack Assembly - Repair Procedures - "Removal")
  2. Remove the safety lever cable bracket mounting bolt (A). Safety lever cable bracket mounting bolt: 7.8 ~ 11.8 N·m
  3. Loosen the mounting bolt and remove the upper case (A). High voltage battery upper case mounting bolt: 7.8 ~ 11.8 N·m
  4. Disconnect the RAD wiring connector (A). [Right]
    [Rear]
    [Left]
  5. Loosen the mounting nut and remove the battery module outlet duct (A). Battery module outlet duct mounting nut: 7.8 ~ 11.8 N·m
  6. Loosen the mounting bolt and remove the bracket (A). Rear battery mounting bracket bolt: 7.8 ~ 11.8 N·m
  7. Remove the high voltage power cable cover (A).
  8. Loosen the nut (A), then disconnect the positive (+) high-voltage power cable (B). Positive (+) high-voltage power cable nut: 7.8 - 11.8 N·m
  9. Loosen the nut (A), then disconnect the negative (-) high-voltage power cable (B). Negative (-) high-voltage power cable nut: 7.8 - 11.8 N·m
  10. Remove the inverter bus bar cover (A).
  11. Remove the inverter bus bar (A). Inverter bus bar bolt/nut: 7.8 - 11.8 N·m
  12. Disconnect the positive (+) power supply for the high voltage battery heating control and the ground connector (A). [With High Voltage Battery Heating System]
  13. Disconnect the power relay assembly connector (A).
  14. Loosen the mounting nut and remove the power relay assembly (A). Power relay unit mounting nut: 7.8 ~ 11.8 N·m
  15. Disconnect the BMS ECU connector (A).
  16. Loosen the mounting nut and remove the BMS ECU (A).

    - BMS ECU mounting nut: 7.8 ~ 11.8 N·m

  17. Disconnect the service plug interlock connector (A).
  18. Loosen the nut (A) and remove the service plug cable assembly (B). Service plug cable assembly nut: 7.8 - 11.8 N·m
  19. Loosen the ground bolt (A) and remove the BMS extension wiring (B).

    Ground bolt: 7.8 - 11.8 N·m

  20. Remove the high-voltage battery assembly.
    1. Remove the bolt securing the high-voltage battery assembly. High-voltage battery assembly bolt: 7.8 - 11.8 N·m
    2. Install SST No. 0K375-E4300 (A) to the battery as shown in the illustration below.
      Make sure the eye bolts are fully threaded into the holes so they do not loosen while lifting the battery assembly with the crane jack.
    3. Install SST No. 0K375-E4300 (A) to the crane jack.
    4. Install SST No. 0K375-E4300 and the jack (A).
      • Make sure the hanger hooks and eye bolts are aligned.
      • Adjust the main hanger frame to match the size of the battery assembly.
    5. Remove the high-voltage battery assembly (A).
      Make sure the battery assembly is balanced.
      The battery assembly is divided into left and right battery packs. Be sure to remove the batteries one at a time. The removal order does not matter.
  21. Loosen the harness clamp screw and remove the voltage and temperature sensor harness (A) from the battery pack assembly. [Left]
    [RH]

Installation
  • Be sure to read and observe the "General Safety Information and Caution" before performing any work on the high voltage system. Failure to follow the safety instructions may result in serious electrical injury.
  • Before performing any work, be sure to disconnect high voltage related to the high voltage system (refer to "High Voltage Disconnection Procedure"). Failure to follow safety instructions may result in serious electric shock.
When installing the RAD harness, make sure the connector is installed correctly. [If not correct] 1. Precharge failure. 2. RAD malfunction (incorrectly detects that the high voltage battery is swollen). [Main check points] 1. Make sure the RAD switch is facing down.
2. Be careful not to reverse the RAD module battery No. 1 connector (2 pins) and the BMS extension connector (1 pin) during assembly.
3. Be careful not to reverse the RAD module battery No. 8 connector (2 pins) and the BMS extension connector (1 pin) during assembly.
  1. Install the high voltage battery pack in the reverse order of removal.

Test yourself

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