Hyundai Ioniq: Hybrid Motor Assembly / Hybrid Drive Motor Assembly. Repair procedures

Hyundai Ioniq (AE) 2017-2024 Service Manual / Hybrid Motor System / Hybrid Motor Assembly / Hybrid Drive Motor Assembly. Repair procedures

Inspection
1.
Use the mΩ tester to check the line resistance.
Category
Inspection area
Inspection criteria
Remarks
Resistance
(Line
- Line)
U - V
35.3 mΩ ± 5%
Based on ambient temperature (20°C)
V - W
W - U

2.
Check the temperature sensor resistance.
Category
Inspection area
Inspection criteria
Remarks
Resistance
(Temperature
sensor)
Pin 4 - 8
8kΩ (30°C / 86°F) - 20kΩ (10°C / 50°F)
10 - 30°C / 50 - 86°F

3.
Check the resolver sensor resistance.
Category
Inspection area
Inspection criteria
Remarks
Resistance
(Resolver
sensor)
Pin 1 - 5
11.7 Ω ± 10%
Based on ambient temperature (20°C)
Pin 2 - 6
32 Ω ± 10%
Pin 3 - 7
27 Ω ± 10%

4.
Perform the insulation test.
Category
Inspection area
Inspection criteria
Remarks
Insulation
(Housing,
cover)
W - U - V
10 MΩ↑
DC 540 V,
1 minute
2.5 mA↓
AC 1600 V,
1 minute
Position (resolver) sensor
100 MΩ↑
DC 500 V,
1 minute
Temperature sensor
100 MΩ↑

Removal
1.
Remove the double clutch transmission (DCT) from the vehicle.
(Refer to DCT (Double Clutch Transmission) System - "Double Clutch Transmission".)
2.
Remove the water pump (EWP) (A).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

3.
Disconnect the reservoir hose (A).
   
After disconnecting the hose, block the end to prevent the hydraulic fluid from leaking.
Make sure that the hydraulic fluid does not drop on other components or your body.
If the hydraulic fluid dropped on other components or your body, wash it immediately.
4.
Remove the engine clutch actuator (B).
Tightening torque :
21.6 - 26.5 N.m (2.2 - 2.7 kgf.m, 15.9 - 19.5 lb-ft)

   
When connecting the reservoir hose to the actuator, make sure that the clamp does not interfere with other components.
Completely remove the air from the engine clutch system.
After installing the hose, place the clamp between the markings.
Make sure that the reservoir hose does not get twisted after installation.
After the installation, both wings of the clamp should face the front of the transmission.
Make sure that no foreign substance, such as dust, does not get inside the hose during the transportation, storage and assembly of the components.
5.
Remove the adaptor (A).

   
Make sure that the O-ring is not damaged, scratched, or deformed while mounting the adaptor.
6.
Remove the concentric sleeve cylinder (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.2 lb-ft)

7.
Unscrew the bolts and remove the motor assembly (A).
Tightening torque :
42.2 - 53.9 N.m (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)

Installation
1.
To install, reverse the removal procedure.
   
Before installing the engine clutch actuator, check the assembled state of the O-rings (A).

After tightening bolts temporarily, tighten the bolt completely at the same time with regulation torque.
2.
After replacing the Engine clutch actuator, operate the followings in order using GDS equipment.
(1)
Engine clutch inspection line learning and diagnostic information.

(2)
Removal of air from engine clutch hydraulic pressure line.
   
When using a vacuum-pressure equipment to inject hydraulic fluid, the vacuum pressure should be no more than 2.5 torr and the injection pressure should be between 2.3 - 2.5 bars.
If it is impossible to inject hydraulic fluid using the above condition, be sure to remove air from the hydraulic line of the engine clutch at a temperature between 0 - 40°C.

(3)
Engine clutch/motor resolver adaptation.

(4)
Stabilization of the engine clutch hardware transfer torque.

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