Hyundai Ioniq: High Voltage Battery System / Battery Pack Assembly. Repair procedures

Hyundai Ioniq (AE) 2017-2024 Service Manual / Hybrid Control System / High Voltage Battery System / Battery Pack Assembly. Repair procedures

Removal
   
Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
1.
Shut off the high voltage.
(Refer to Hybrid Control System - "High voltage Shut-off Procedures")
2.
Remove the rear seat cushion.
(Refer to Body - "Rear Seat Assembly")
3.
Remove the rear door scuff trim.
(Refer to Body - "Door Scuff Trim")
4.
Remove the upper frame (A) after loosening the mounting bolts and nuts.

5.
Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts.

6.
Remove the inlet cooling duct.
(Refer to Hybrid Control System - "Cooling Duct")
7.
Remove the high voltage power cable (+) terminal (A) and (-) terminal (B) after loosening the mounting bolts.

8.
Disconnect the inverter power connector [+] (A), inverter power connector [-] (B) and battery current sensor connector (C).
9.
Disconnect the PRA connector (D).

10.
Remove the installation bolt (A) and nut (B), then remove the power relay assembly.

11.
Remove the installation bolts and nut, then remove the high voltage battery front cover (A).

12.
Disconnect the BMS connector (A).
13.
Remove the installation nut (B), then remove the BMS.

14.
Remove the outlet cooling duct.
(Refer to Hybrid Control System - "Cooling Duct")
15.
Disconnect the cooling fan connector (A).
16.
Remove the installation nut (B), then remove the safety plug cable.

17.
Remove the installation bolts and nut (A), then remove the cooling fan.

18.
Remove the installation bolts,then remove the high voltage battery pack (A).

Installation
   
Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
1.
Install the high voltage battery pack in the reverse order of removal.
BMS Installation nut :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
PRA Installation nut :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
Inverter power cable terminal tightening nut :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
High voltage battery pack assembly installation bolt :
78.4 - 117.7N.m (8.0 - 12.0 kgf.m, 57.9 - 86.8lb-ft)

    Inspection

    Inspection[Battery Pack Assembly Troubleshooting Chart]    • For SOC check, refer to "SOC Inspection"• For voltage check, refer to "Battery Voltage Inspection"• For battery voltage sensing circuit, refer to "Voltage Sensing Circuit Inspection"• For isolation resistance check, refer to "Isolation Resistance Inspection" [SOC Level and Follow-up] SOC Symptom Warning Lamp Follow-up MIL Service Fuel • Normal ---  10 - 15% • Motor torque limite (Acceleration delay)--ON• Refuel and check the SOC againON--• Repair the MIL or Service Lamp related system• Charge the battery by starting the engine• Refuel if necessary ONON--ON-OnONON 5 - 10% • EV Mode inhibited • FATC Inhibited • LDC Inhibited --ON• Refuel and check the SOC againON--• Repair the MIL or Service Lamp related system• Charge the battery by starting the engine • Refuel if necessaryONON--ON-ONONON 0 - 5% • Impossible to start ON--• Repair the MIL or Service Lamp related system• Start the engine with GDS to charge the battery• Refuel if necessary ONON--ON-ONONON 0% ON--• Repair the MIL or Service Lamp related system• If necessary, Replace Battery Pack• Refuel if necessary [SOC Inspection]1...

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    Rear Seats

    Folding the rear seat

    The rear seatbacks can be folded to facilitate carrying long items or to increase the luggage capacity of the vehicle.

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