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Kia EV6: Sub Battery Pack Assembly (Sub-BPA)

Component

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

1. Upper Case Bolt
1-a. 103.0 - 154.9 N·m (10.5 - 15.8 kgf·m, 75.9 - 114.3 lb·ft)
2. O-ring
3. Watertight Bracket
3-a. 1st : 8.8 N·m (0.9 kgf·m, 6.5 lb·ft)
3-a. 2nd : 10.8 N·m (1.1 kgf·m, 8.0 lb·ft)
4. Upper Case
5. Waterproof Gasket
6. Sub Battery Pack Assembly (Sub-BPA)
6-a. 7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)
7. Battery Module Assembly (BMA)
7-a. 19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)


Special Service Tool

Tool Name / Number Illustration Description
High Voltage Battery Module Assembly transport hanger
09375 - GI700

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Used to transferring the high voltage Sub Battery Pack Assembly (Sub-BPA)
High voltage battery module surface pressure jig
09375 - GI800

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Used for compressing the high voltage Sub Battery Pack Assembly (Sub-BPA)
High voltage battery module guide
09375 - GI900

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Used for seating the high voltage battery module on the surface pressure jig
High voltage battery module disassembly jig
TMS - 1907

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Used for disassembling the high voltage Sub Battery Pack Assembly (Sub-BPA)

Removal

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.

• When working on high voltage system or related components, 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 high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

Do not step on or apply a load when removing the Sub Battery Pack Assembly (Sub-BPA). The lower part of the Sub-BPA may break if a load is applied.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• Install the high voltage battery module surface pressure jig and guide before using the high voltage battery module disassembly jig. (Refer to the equipment manufacturer's manual)

• The procedure for removing the Sub Battery Pack Assembly (Sub-BPA) below is for #1. Other Sub-BPAs are performed in the same procedures.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

1.Remove the Battery System Assembly (BSA) upper case.(Refer to High Voltage Battery System - "Case")

2.Remove the bus bar (A) after removing the bolt and nut.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

3.Remove the bus bar (A) after removing the bolt and nut.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

4.Remove the bus bar (A) after removing the bolts.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

5.Disconnect the voltage & temperature sensing wiring connector (A).

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

6.Remove the voltage & temperature sensing wiring (A) after disconnecting the connector (B).

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

7.Open the bus bar covers (A).

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

8.Remove the bus bar (A) after removing the bolts.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

9.Remove the bus bar (A) after removing the bolt and nut.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

10.Remove the bus bar (A) after removing the bolts.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

11.Remove the wiring pad (A).

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

The existing double-sided tape should be replaced with new ones. (Do not reuse)

12.Remove the mounting bracket (A) after removing the bolts.

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

13.Remove the bolts and nuts of Sub Battery Pack Assembly (Sub-BPA) (A).

Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

14.After installing the high voltage battery module assembly hanger (09375 - GI700), separate the Sub-BPA from the lower case.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• Work on the high voltage battery module disassembly jig (TMS - 1907) by installing the removed Sub-BPA to it.

• Note for handling as damage and deformation on the lower side of the Sub-BPA may cause fire.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

Refer to the equipment manufacturer's manual for how to use battery module assembly hanger (09375 - GI700).

15.Transfort the Sub-BPA using the crane jack.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

16.Install the removed Sub-BPA (A) on high voltage battery module assembly disassembly jig (B).

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

For detailed instructions on how to use it, refer to the manual of manufacturer of Battery Module Disassembly jig (TMS - 1907).

17.Remove the remaining gap filler on the Sub-BPA downside surface and the lower case.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• Carefully remove the gap filler so that the lower part of the module is not deformed after wearing the insulating gloves.

• Remove with the plastic remover to prevent scratches on the lower case.

• Be careful not to contact the bottom of the module when the air gun is used.

Installation

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.

• When working on high voltage system or related components, 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 high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.

1.Perform the cell balancing procedures when the Battery Module Assembly (BMA) is replaced with a new one.(Refer to High Voltage Battery System - "Battery Module Assembly (BMA)")

2.Apply a new gap filler using the tools.(Refer to High Voltage Battery System - "Gap Filler Application")

3.Install in the reverse order of removal.

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

• Install the Sub Battery Pack Assembly (Sub-BPA) to the specified torque.

• If the Sub-BPA is dropped, it may cause internal damage. (Do not reuse)

4.Perform the High Voltage Battery Pack Connector Check with the KDS before installing the Battery System Assembly (BSA) upper case.(S/W Management → Battery Management System (BMS) → High Voltage Battery Pack Connector Check)

5.Perform the air tightness inspection with the KDS.(Refer to High Voltage Battery System - "Air tightness Inspection")

6.Perform the SOC calibration with the KDS.(S/W management → Battery Management System (BMS) → SOC Calibration)

Kia EV6. Sub Battery Pack Assembly (Sub-BPA)   

Refer to the KDS screen for operating conditions and details.

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    Component 1. Upper Case Bolt 1-a. 103.0 - 154.9 N·m (10.5 - 15.8 kgf·m, 75.9 - 114.3 lb·ft) 2. O-ring 3. Watertight Bracket 3-a. 1st : 8.8 N·m (0.9 kgf·m, 6.5 lb·ft) 3-a. 2nd : 10. ...

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