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

Hyundai Ioniq (AE) 2017-2025 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...

    Sub Battery Pack Assembly (Sub-BPA). Repair procedures

    Check the target charging voltage when replacing with a new module Fault Code1.Turn OFF the ignition switch.2.Connect the diagnostic tool device to the self-diagnosis connector (DLC)...

    Other information:

    Hyundai Ioniq (AE) 2017-2025 Service Manual: Engine Control Module (ECM). Schematic diagrams


    ECM Terminal and Input / Output SignalECM Terminal FunctionConnector [C100-A] Pin No Description Connected to 1Injector (Cylinder #3) [Low] control outputInjector (Cylinder #3)2Injector (Cylinder #4) [High] control outputInjector (Cylinder #4)3Injector (Cylinder #3) [Low] control outputInjector (Cylinder #3)4Vehicle speed signal outputCluster5EGR Valve (Motor -)EGR Valve6Sensor power (+5V)Throttle Position Sensor (TPS) 1, 27Sensor power (+5V)EGR Valve8Knock Sensor (KS) signal inputKnock Sensor (KS)9Camshaft Position Sensor (CMPS) [Bank 1 / Exhaust] signal inputCamshaft Position Sensor (CMPS) [Bank 1 / Exhaust]10-11Brake Switch [test] signal inputBrake Switch12Brake Switch [lamp] signal inputBrake Switch13-14-15-16Injector (Cylinder #3) [High] control outputInjector (Cylinder #3)17Injector (Cylinder #1) [High] control outputInjector (Cylinder #1)18Injector (Cylinder #1) [Low] control outputInjector (Cylinder #1)19-20EGR Valve (Motor +)EGR Valve21Sensor shieldKnock Sensor (KS)22Sensor groundKnock Sensor (KS)23-24Sensor groundCamshaft Position Sensor (CMPS) [Bank 1 / Exhaust]25-26-27-28-29-30-31Injector (Cylinder #2) [High] control outputInjector (Cylinder #2)　32-33ETC Motor [-] control outputETC Motor34Sensor groundThrottle Position Sensor (TPS) 1, 235Throttle Position Sensor (TPS) 1 signal inputThrottle Position Sensor (TPS) 136Sensor groundRail Pressure Sensor (RPS)37Rail Pressure Sensor (RPS) signal inputRail Pressure Sensor (RPS)38-39Camshaft Position Sensor (CMPS) [Bank 1 / Intake] signal inputCamshaft Position Sensor (CMPS) [Bank 1 / Intake]40-41-42-43VS-/IP- (Common Ground for VS, IP)Heated Oxygen Sensor [Bank 1 / Sensor 1]　44Rc (Compensative Resistance)Heated Oxygen Sensor [Bank 1 / Sensor 1]　45Sensor groundHeated Oxygen Sensor [Bank 1 / Sensor 2]　46Injector (Cylinder #2) [Low] control outputInjector (Cylinder #2)47-48ETC Motor [+] control outputETC Motor49-50Throttle Position Sensor (TPS) 2 signal inputThrottle Position Sensor (TPS) 251Sensor power (+5V)Rail Pressure Sensor (RPS)52Electrical load signal inputWiper Motor53Sensor groundCamshaft Position Sensor (CMPS) [Bank 1 / Intake]54Sensor groundEGR valve55EGR valve (Feedback signal)EGR valve56-57-58VS+ (NERNST Cell Voltage)Heated Oxygen Sensor [Bank 1 / Sensor 1]　59Rc/Rp (Pump Cell Voltage)Heated Oxygen Sensor [Bank 1 / Sensor 1]　60Heated Oxygen Sensor [Bank 1 / Sensor 2] signal inputHeated Oxygen Sensor [Bank 1 / Sensor 2]　Connector [C100-K] Pin No Description Connected to 1ECM GroundChassis Ground2Battery power (B+)Main Relay3ECM GroundChassis Ground4Battery power (B+)Main Relay5ECM GroundChassis Ground6Battery power (B+)Main Relay7Fuel Pressure Control Valve [High] control outputFuel Pressure Control Valve8-9-10Engine Coolant Temperature Sensor (ECTS) signal [EGR Cooler Tube]Engine Coolant Temperature Sensor (ECTS) [EGR Cooler Tube]11Sensor groundEngine Coolant Temperature Sensor (ECTS) [EGR Cooler Tube]12Vehicle speed signal inputIntegrated brake actuation unitSmart key Control Module13-14-15Accelerator Position Sensor (APS) 2 signal inputAccelerator Position Sensor (APS) 216Sensor power (+5V) Accelerator Position Sensor (APS) 217Sensor power (+5V) Manifold Absolute Pressure Sensor (MAPS)18Sensor power (+5V) Accelerator Position Sensor (APS) 119Accelerator Position Sensor (APS) signal inputAccelerator Position Sensor (APS) 120Sensor power (+5V) Crankshaft Position Sensor (CKPS) A/C Pressure Transducer (APT)21-22-23-24Fuel Pump Relay control outputFuel Pump Relay25-26-27-28-29Fuel Pressure Control Valve [Low] control outputFuel Pressure Control Valve30A/C Pressure Transducer (APT) signal inputA/C Pressure Transducer (APT)31-32Crankshaft Position Sensor (CKPS) signal inputCrankshaft Position Sensor (CKPS) 33-34-35-36-37Sensor groundAccelerator Position Sensor (APS) 238Manifold Absolute Pressure Sensor (MAPS) signal inputManifold Absolute Pressure Sensor (MAPS)39Intake Air Temperature Sensor (IATS) signal inputIntake Air Temperature Sensor (IATS)40Sensor groundManifold Absolute Pressure Sensor (MAPS)41Sensor groundAccelerator Position Sensor (APS) 142-43-44Mass Air Flow Sensor (MAFS) signal inputMass Air Flow Sensor (MAFS) 45Sensor groundMass Air Flow Sensor (MAFS) 46Engine Control Relay control outputMain Relay47CVVT Oil control solenoid (OCS) [Bank 1 / Intake] control outputCVVT Oil control solenoid (OCS) [Bank 1 / Intake]48-49-50-51Battery power (B+)Ignition Switch52-53-54Sensor groundCrankshaft Position Sensor (CKPS) 55P-CAN [High]Other control module, Data Link Connector (DLC), Multi-Purpose Check Connetor56H-CAN [High]Other control module, Data Link Connector (DLC), Multi-Purpose Check Connetor57-58Immobilizer communication lineSmart key Control Module59-60Engine Coolant Temperature Sensor (ECTS) signal input [Water Temperature Control Assembly]Engine Coolant Temperature Sensor (ECTS) [Water Temperature Control Assembly]61Sensor groundEngine Coolant Temperature Sensor (ECTS) [Water Temperature Control Assembly]62Fuel Level Sender (FLS) signal inputFuel Level Sender (FLS)63-64Ignition Coil (Cylinder #2) control outputIgnition Coil (Cylinder #2)65Ignition Coil (Cylinder #3) control outputIgnition Coil (Cylinder #3)66-67-68Cooling Fan Relay control outputCooling Fan Relay69-70CVVT Oil Control (OCV) Valve [Bank 1 / Exhaust] control outputCVVT Oil Control Valve (OCV) [Bank 1 / Exhaust] 71- 72- 73Battery power (B+)Battery74- 75Sensor groundA/C Pressure Transducer (APT)76LIN communication signal inputBattery Sensor77P-CAN [Low]Other control module, Data Link Connector (DLC), Multi-Purpose Check Connetor78H-CAN [Low]Other control module, Data Link Connector (DLC), Multi-Purpose Check Connetor79- 80- 81- 82- 838485- 86Ignition Coil (Cylinder #4) control outputIgnition Coil (Cylinder #4)87Ignition Coil (Cylinder #1) control outputIgnition Coil (Cylinder #1)88- 89- 90-91Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor1] Heater control outputHeated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1]92Heated Oxygen Sensor (HO2S) [Bank 1 / Sensor2] Heater control outputHeated Oxygen Sensor (HO2S) [Bank 1 / Sensor 1]93Purge Control Solenoid Valve (PCSV) control outputPurge Control Solenoid Valve (PCSV)94-ECM Terminal Input/Output Signal Connector [C100-A] Pin No Description Condition Type Level 1IInjector (Cylinder #3) [Low] control outputRelay OFFDC71VRelay ONMax 1...

    Hyundai Ioniq (AE) 2017-2025 Service Manual: Repair procedures


    Removal1.Disconnect the battery negative cable from the battery and then wait for at least 30 seconds.2.Turn the steering wheel so that the front wheels are placed in the straight ahead position.3.Remove the driver airbag module (DAB).    • Insert the end of the flat tool along the guide hole...

    Categories

    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.

    WARNING

    Never allow passengers to sit on top of the folded down seatback while the vehicle is moving. This is not a proper seating position and no seat belts are available for use. This could result in serious injury or death in case of an accident or sudden stop. Objects carried on the folded down seatback should not extend higher than the top of the front seatbacks. This could allow cargo to slide forward and cause injury or damage during sudden stops.

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