Special Service Tool

Tool Name / Number	Illustration	Description
Used to fill the coolant for EV 0K253 - J2300		Used to fill and drain coolant in the high voltage battery system assembly

SST (0K253 - J2300) Detail Name

1. Pressure Valve
2. Suction Valve
3. Vacuum Valve 1
4. Vacuum Valve 2
5. Coolant Injection
6. Vacuum Valve
7. Regulator Pressure Gauge
8. Pressure Gauge
9. Vacuum Gauge
10. Air Pressurization Valve
11. Vacuum Outlet Valve
12. Air Hose Inlet Valve
13. Regulator Adjusting Knob

Coolant Refilling And Air Bleeding

   

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

• When working a high voltage system, the technician must be recognized and observe "General Safety Information and Caution". If do not follow, serious accidents like electric shock and short circuit are caused.

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

   

• Use a fender cover to protect the painted surface.

• Be careful not to damage the connector when disconnecting.

• Follow the instructions below when releasing the quick connector.- Remove the while pressing the quick connector clamp (A) in the direction of the arrow.- Do not touch the rubber seal (B) inside the hose.

• Check the color of the coolant in the pressure cap label and reservoir tank when replacing or replacing the coolant.

1.Disconnect the battery negative ( - ) terminal and the service interlock connector.(Refer to Battery Control System - "Auxiliary 12 V Battery - 2WD")(Refer to Battery Control System - "Auxiliary 12 V Battery - 4WD")

2.Open the reservoir tank pressure cap (A).

3.Install the radiator cap adapter (A).

4.Install the radiator cap connection hose (A) to the radiator cap adapter (B).

5.Connect the radiator cap connection hose (A) to the air pressurization valve of the SST (0K253 - J2300).

6.Install the air hose (A) to the air inlet valve of the SST (0K253 - J2300).

7.Turn the regulator adjusting knob (A) to set pressure gauge (B) to 0.2 Mpa.

8.Remove the front under cover.(Refer to Motor and Reduction Gear System - "Front Under Cover")

9.Disconnect the battery Electric Water Pump (EWP) cooling hose (A) after releasing the quick connector.[2WD]

[4WD]

10.Install the coolant drain adapter and hose (A) to the battery EWP and EWP cooling hose.[2WD]

[4WD]

11.Put the opposite of the coolant drain adapter and hose (A) to a bucket (B).

12.Turn the pressurization valve (A) of the SST (0K253 - J2300) in the direction of the arrow to drain coolant.

   

Make sure that the valves other than the pressurized valve (A) are closed.

13.Close the pressurization valve after drain coolant, and then install the battery EWP cooling hose (A).[2WD]

[4WD]

14.Remove the rear under cover.(Refer to Motor and Reduction Gear System - "Rear Under Cover")

15.Disconnect the water pump hose (A) after releasing the quick connector.

16.Install the coolant drain adapter and hose (A) to the water hose.

17.Put the opposite of the coolant drain adapter and hose (A) to a bucket (B).

18.Turn the pressurization valve (A) of the SST (0K253 - J2300) in the direction of the arrow to drain coolant.

   

Make sure that the valves other than the pressurized valve (A) are closed.

19.Close the pressurization valve after drain coolant, and then install the water hose (A).

20.Drain coolant and inside the reservoir tank, and then clean it.

21.Disconnect the radiator cap connection hose (A) to the pressurization valve on the SST (0K253 - J2300).

22.Connect the radiator cap connection hose (A) to the vacuum valve of the SST (0K253 - J2300).

23.Open the vacuum valve (A) of the SST (0K253 - J2300) in the direction of the arrow, and then close when the vacuum gauge (B) reaches the green area (C).

   

Make sure that the valves other than the vacuum valve (A) are closed.

24.Connect the coolant suction hose (A) to the SST (0K253 - J2300) coolant filler valve and place the opposite hose in the bucket (B) containing new coolant.

25.Turn the suction valve (A) in the direction of the arrow to fill new coolant, and then close it when the vacuum gauge reaches to '0'.

Battery Type	Coolant	Specification
		160kW(2WD)	70kW+160kW(4WD)
Standard (ℓ)	Normal Coolant (Pink color)	17.7	17.9
Long range (ℓ)		19.4	19.6

   

• Use only genuine antifreeze.

• Do not mix antifreeze/coolant from different brands.

• Do not add any anti-rust.

• Use only distilled water when mixing antifreeze with water.

• For best corrosion protection, the coolant concentration must be maintained year-round at 45% (except for North America, Europe and China: 55%) minimum.Coolant concentrations less than 45% (except for North America, Europe and China: 55%) may not provide sufficient protection against corrosion or freezing.

• Coolant concentrations greater than 60% will impair cooling efficiency and are not recommended.

• General Area : 45 - 50%Frigid Area : 55 - 60%

   

Check that the valve except the suction valve (A) is locked.

26.Remove the radiator cap adapter (A).

27.Connect the KDS and perform the "Electric Water Pump Control" on the S/W management menu.

   

Visually check the tank for good coolant circulation during EWP operation after air bleeding.

   

Charge the auxiliary 12 V battery during performing "Electric Water Pump Control" to prevent battery drain.

28.When the Electric Water Pump (EWP) begins to operate and the coolant begins to circulate, fill the reservoir tank with coolant.

   

• Friction may damage the bearing if the EWP is operated without coolant.

• If the coolant circulation is not smooth or air bubbles are still visible, repeat step 27 - 28.

• Operate the battery EWP until the air bleeding is complete.

29.Connect the KDS, and then perform the "Battery EWP Operation Mode for Degassing and circulation.

   

Visually check the tank for good coolant circulation during EWP operation after air bleeding.

   

Charge the auxiliary 12 V battery during performing "Battery Electric Water Pump Control" to prevent battery drain.

30.When the battery Electric Water Pump (EWP) begins to operate and the coolant begins to circulate, fill the reservoir tank with coolant.

   

• Friction may damage the bearing if the EWP is operated without coolant.

• If the coolant circulation is not smooth or air bubbles are still visible, repeat step 29 - 30.

• Operate the battery EWP until the air bleeding is complete.

31.Stop the battery EWP operation after air bleeding, and then fil coolant until "MAX" line of the reservoir tank and install the reservoir cap.

   

• If the noise is less during EWP operation and there is no air bubbles in the reservoir tank, the cooling system air bleeding is complete.

• The cooling system air bleeding and coolant injection are performed perfectly when the coolant is completely cooled. Check the coolant level of the reservoir tank for 2 - 3 days after flushing the coolant.

• Make sure the quick connector (A) is installed securely.

32.Start the vehicle and then check the coolant hose and pipe connections for leakage.

33.Install the front under cover.(Refer to Motor and Reduction Gear System - "Front Under Cover")

34.Install the rear under cover.(Refer to Motor and Reduction Gear System - "Rear Under Cover")