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Hyundai Tucson: 48V Battery System -  Repair procedures (Removal)

Hyundai Tucson - Fourth generation (NX4) - (2020-2023) - Workshop Manual / Engine Electrical System / 48V Battery System / 48V Battery System -  Repair procedures (Removal)

  1. Turn ignition switch OFF and disconnect the battery (-) terminal.
  2. Remove the 48V battery assembly.

(Refer to 48V Battery System - "Repair procedures")

  1. Remove the battery cover (A) after loosening the mounting bolts.

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

  1. Remove the terminal capacitor (A) after loosening the mounting bolts.

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

  1. Remove the mounting nuts and remove the battery module (-) busbar (A).

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

  1. Remove the mounting nuts and remove the battery module (+) busbar (A).

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

  1. Remove the BMS wiring harness terminal after loosening the mounting bolts (A).

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

  1. Remove the 48V battery case assembly after loosening the mounting bolts (A).

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

  1. Disconnect the PRA extension connector (A) and the BMS & LDC connectors (B).
  2. Disconnect the battery temperature sensor extension connector (C).

  1. Disconnect the cooling blower fan connector (A).

  1. Remove the battery cooling blower unit (B) from the battery module (A).

Tightening torque : 5.9 - 9.8 N.m (0.6 - 1.0 kgf.m, 4.3 - 7.2 lb-ft)

  1. Remove the battety module lnlet duct (A) after loosening mountin bolts.

Tightening torque : 3.4 - 6.4 N.m (0.35 - 0.65 kgf.m, 2.5 - 4.7 lb-ft)

Installation

Installation

  1. Install in the reverse order of removal.

Description

The Power Relay Assembly (PRA) consists of the positive main relay. It is located inside the battery pack assembly and controls the high voltage power circuit between the high voltage battery and inverter by the control signal of BMS ECU.

Removal

  1. Turn ignition switch OFF and disconnect the battery (-) terminal.
  2. Remove the battery cover (A) after loosening the mounting bolts.

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

  1. Disconnect the PRA extension connector (A).

  1. Remove the terminal capacitor (A) after loosening the mounting bolts.

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

  1. Remove the mounting nuts and remove the battery module (-) busbar (A).

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

  1. Remove the mounting nuts and remove the battery module (+) busbar (A).

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

  1. Remove the PRA assembly (A) after loosening the mounting bolts (B).

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

Installation

Installation

  1. Install in the reverse order of removal.

    READ NEXT:

     BMS ECU Terminal and Input/Output Signal

    Terminal Function Connector B10-A Connector B01-B Removal Turn ignition switch OFF and disconnect the battery (-) terminal. Remove the 48V battery assembly. (Refer to 48V Battery System - "Repair procedures")

     Power Relay Assembly (PRA) - Removal

    Removal Remove the PRA assembly. (Refer to 48V Battery System - "Power Relay Assembly (PRA)") Remove the PRA cover. Remove the mounting bolts and remove the power relay busbar (A). Disconnect the main relay connector

     Battery Pack Assembly Inlet Duct/ Battery Pack Assembly Outlet Duct

    Removal and Installation Battery Pack Assembly Inlet Duct Turn the ignition switch OFF and disconnect the battery (-) terminal. Remove the luggage board (A). Separate the inlet cooling duct (A) in the direction of the arrow. Tigh

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    Component Location Front pillar trim Replacement WARNING When removing with a flat-tip screwdriver or remover, wrap protective tape around the tools to prevent damage to components. Put on gloves to prevent hand injuries. WA

     Special driving conditions

    Hazardous driving conditions When hazardous driving elements are encountered such as water, snow, ice, mud and sand, take the following precautions: Drive cautiously and maintain a longer braking distance. Avoid abrupt braking or steering

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