Hyundai Ioniq: High Voltage Battery System / Power Relay Assembly (PRA). Repair procedures

Hyundai Ioniq (AE) 2017-2025 Service Manual / Hybrid Control System / High Voltage Battery System / Power Relay Assembly (PRA). 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, and BMS ECU extension connector (E).

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

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.

Install the power relay assembly in the reverse order of removal.

PRA Installation nut :

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

High voltage power cable terminal tightening nut :

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

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D..