Hyundai Ioniq: Hybrid Control System / HPCU (Hybrid Power Control Unit). Repair procedures

Hyundai Ioniq (AE) 2017-2024 Service Manual / Hybrid Control System / Hybrid Control System / HPCU (Hybrid Power Control Unit). 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.
Be sure to shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
Hybrid Power Control Unit (HPCU)
1.
Shut off the high voltage circuit.
(Refer to Hybrid Control System - "High Voltage Shutoff Procedure")
2.
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechanical System - "Air Cleaner")
3.
Remove the ECM & TCM bracket assembly.
(Refer to Engine Control/Fuel System - "Engine Control Module")
4.
Drain the coolant of hybrid motor cooling system.
(Refer to Hybrid Motor Cooling System - "Coolant")
5.
Disconnect the motor power cable connector (A) and HSG power cable connector (B) after loosening the mounting bolts.

6.
Disconnect the power cable (A) and inverter power cable (B) from the HPCU.

   
Remove the inverter power cale in the follwing order.

7.
Disconnect the HCU & inverter (MCU) connector (A).

8.
Disconnect the coolant outlet hose & pipe after loosening the mounting bolt (A).

9.
Disconnect the coolant inlet hose quick-connector (A).
10.
Remove the LDC power outlet cable mounting bolt (B) and ground cable bolt (C).

11.
Remove the HPCU (A) after loosening the mounting bolts.

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 HPCU in the reverse order of removal.
Power cable connector installation bolt :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
HPCU installation bolt :
21.6 - 23.5 N.m (2.2 - 2.4 kgf.m, 15.9 - 17.4 lb-ft)
LDC power otulet cable installation bolt :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
LDC ground cable installation bolt :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
2.
Refill the hybrid motor cooling system coolant and perform air bleeding by using the GDS.
(Refer to Hybrid Motor Cooling System - "Coolant")
   
Perform HCU Variant Coding and Engine Clutch / Motor Resolver learning after replacing the HPCU.
HCU Variant Coding
1.
Turn the ignition switch OFF.
2.
Connect the KDS / GDS to Data Link Connector (DLC).
Turn the ignition switch ON.
3.
Select "Vehicle, Model year, Engine, System".
4.
Select "Vehicle S/W Management".
5.
Select "HCU Variant Coding".

Engine Clutch / Motor Resolver Adaptation
1.
Turn the ignition switch OFF.
2.
Connect the KDS / GDS to Data Link Connector (DLC).
Turn the ignition switch ON.
3.
Select "Vehicle, Model year, Engine, System".
4.
Select "Vehicle S/W Management".
5.
Select "Engine clutch/motor resolver adaptation.".

    HPCU (Hybrid Power Control Unit). Components and components location

    Components1. Hybrid Control Unit (HCU)2. Inverter3. Low DC/DC Converter (LDC)4. Connector (↔ High Voltage Battery)5. Connector (↔ Motor)6. Connector (↔ HSG)7...

    HCU (Hybrid Control Unit). Schematic diagrams

    HCU Terminal and Input / Output SignalTerminal FunctionConnector [C133-S] Pin No Description Connected to 1HCU GroundChassis ground2HCU GroundChassis ground3HCU GroundChassis ground4Battery power (B+)Battery5Battery power (B+)Battery6Battery power (B+)Battery7- 8- 9- 10- 11- 12- 13- 14- 15Brake Switch 2 signal inputBrake Switch (NC, IG1)16Brake Switch 1 signal inputBrake Switch (NO, B+)17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 31-32-33-34- 35- 36- 37- 38Start signal inputSmart Key Unit39- 40- 41- 42- 43- 44- 45- 46- 47- 48- 49- 50- 51- 52- 53- 54- 55- 56- 57- 58- 59- 60- 61- 62- 63- 64- 65- 66- 67- 68- 69- 70- 71- 72- 73IGN signal inputSmart Key Unit74- 75- 76- 77- 78Powertrain CAN [High] signal inputOther control modules79Powertrain CAN [Low] signal inputOther control modules80- 81Hybrid CAN [High] signal inputOther control modules82Hybrid CAN [Low] signal inputOther control modules83- 84- 85- 86- 87- 88- 89- 90- 91- 92- 93- 94- Input/Output signalConnector [C133-S] Pin no Description Condition Type Level 1HCU GroundAlwaysDC VoltageMax...

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