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

Main Relay 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
12steps
~72min
3/5difficulty
Done 0 of 12

Inspection
  • 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 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.

Main Relay (-) Inspection

[Using Multimeter (Relay OFF)]
  1. Disconnect high voltage. (Refer to High Voltage Battery Management System - "High Voltage Disconnection Procedure")
  2. Remove the upper cover of the high voltage battery. (Refer to High Voltage Battery System - "Housing")
  3. Measure the resistance between the high voltage power terminal (-) and the inverter terminal (-).

    Specification: ?? Ω (20°C)

  4. Disconnect high voltage. (Refer to High Voltage Battery Management System - "High Voltage Disconnection Procedure")
  5. Remove the upper cover of the high voltage battery. (Refer to High Voltage Battery System - "Housing")
  6. Connect SST No.: 0K918-E4100, 0K375-E4100, 0K375-E4200 to the vehicle.
  7. Connect GDS to the DLC.
  8. Turn the ignition on.
  9. Activate the main relay (-) using the "Operation Check" on the GDS, as shown in the figure below.
[Using GDS (Relay ON)]

Main Relay Coil Resistance

  1. Disconnect high voltage. (Refer to High Voltage Battery Management System - "High Voltage Disconnection Procedure")
  2. Remove the Power Relay Assembly (PRA). (Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
  3. Measure the resistance of the main relay (+) (between No. 6 and No. 10) and the main relay (-) (between No. 4 and No. 6).

    Specification: 21.6 ~ 26.4 ? (20°C)

Removal
The main relay, precharge relay, precharge resistor, battery current sensor, high voltage battery heater relay and high voltage battery heater fuse are built into the Power Relay Assembly (PRA). Refer to the Power Relay Assembly (PRA) removal procedure.

Installation
The main relay, precharge relay, precharge resistor, battery current sensor, high voltage battery heater relay and high voltage battery heater fuse are built into the Power Relay Assembly (PRA). Refer to the Power Relay Assembly (PRA) installation procedure.

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