2017 Hyundai IONIQ Electric Service and Repair Manual (AE EV 88kW)

Electric Powertrain and Drivetrain

• 88 kW (118 HP) Permanent Magnet Synchronous Electric Motor (EM09)
• 28.0 kWh High-Voltage Lithium-ion Polymer Battery Pack
• Single-Speed Automatic Reduction Gear Transmission

• Complete electric motor assembly and housing servicing
• Bearing replacement and specialized E-Axle repair procedures
• High-voltage traction battery cell balancing and module diagnostic workflows
• Liquid-cooling system repairs for the electric motor and Inverter/LDC assembly
• Single-speed reduction gear oil replacement and overhaul procedures
• Inverter and Power Control Unit (EPCU) troubleshooting
• Front-wheel drive axle and constant velocity (CV) joint servicing

Chassis and Suspension

• Front Suspension: Independent MacPherson strut repair with gas shock absorbers
• Rear Suspension: Coupled Torsion Beam Axle (CTBA) layout servicing (exclusive to the EV variant)
• Motor-Driven Power Steering (MDPS rack and pinion) diagnostics
• Wheel alignment specifications and adjustment points
• Wheel bearing and hub replacement
• Trailing arm, bushing, and structural axle inspections

Braking Systems

• Hydraulic disc braking system (front and rear)
• Regenerative Braking System (Paddle Shifter Controlled Energy Recovery)
• Anti-lock Braking System (ABS) and Electronic Brakeforce Distribution (EBD)
• Electronic Stability Control (ESC) and Vehicle Stability Management (VSM)
• Electronic Parking Brake (EPB) servicing, motor replacement, and calibration (where equipped)
• Integrated Brake Actuator system bleeding and pressure calibration procedures

Electrical and Wiring

• Complete factory wiring diagrams
• 12V auxiliary system servicing (with 12V battery saver charging logic)
• High-voltage Power Distribution Unit (PDU) schematics
• Onboard Charger (OBC – 6.6 kW AC) and charging inlet port diagnostics
• Combined Charging System (CCS DC Fast Charging / Type 2 AC) inlet servicing
• Vehicle Control Unit (VCU) and Battery Management System (BMS) diagnostics
• High-speed Controller Area Network (CAN Bus) and LIN Bus troubleshooting
• LED and Halogen lighting system diagnostics
• Instrument cluster and dedicated EV energy flow display servicing
• 7-inch or 8-inch Touchscreen Infotainment and Navigation
• Smart Key, proximity sensing, and push-button start systems

Air Conditioning and HVAC

• Single-zone automatic climate control diagnostics
• High-Voltage Electric A/C Compressor replacement
• Refrigerant (R-134a or R-1234yf) evacuating and recharging procedures
• PTC heater system repairs for electric cabin heating
• High-voltage heat pump system component servicing (where equipped)
• HVAC control module diagnostics and blend door calibrations

Body and Interior

• Interior trim, center console, electronic shift-by-wire button console, and dashboard removal
• Door components, power windows, and central locking
• Smart cruise control radar and lane-keep assist camera alignment
• Supplementary Restraint System (SRS) airbag component replacement
• High-voltage battery service plug isolation and lock-out tag-out safety procedures

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup tables
• Factory diagnostic workflows and EV system safety steps
• Scan tool specialized procedures (shift-by-wire calibration, battery state-of-health)
• Live data parameter interpretation
• Sensor and actuator testing specifications

Common Error Codes Covered

Electric Motor & EV Powertrain Codes

• P0A0C: High Voltage System Interlock Circuit Low
• P0A1B: Drive Motor Control Module Performance
• P0A78: Drive Motor Inverter Performance

Battery Management Codes

• P0AA6: High Voltage System Isolation Fault
• P0AC4: Hybrid/EV Battery Pack Main Relay Control Circuit Malfunction
• U1008: BMS Communication Timeout

ABS, EPB, & Chassis Codes

• C1202: ABS Wheel Speed Sensor Front-LH Circuit Malfunction
• C1604: ESC ECU Malfunction
• C2402: Motor-Pump Circuit Failure (ABS/ESC)

Network Communication Codes

• U0100: Lost Communication with VCU/ECM
• U0110: Lost Communication with Drive Motor Control Module
• U0298: Lost Communication with DC-to-DC Converter Control Module

Body Control Codes

• B1603: CAN Communication Circuit Error (BCM)
• B2513: Smart Key System Circuit Malfunction

Fuse Box Diagram

• Engine compartment E-room fuse box (including high-voltage safety fuses)
• Passenger compartment fuse panel (instrument panel cluster side)
• Fuse amperage ratings and circuit identification
• Relay locations and circuit power distribution diagrams

Cooling System Routing Diagrams

• Powertrain liquid-cooling loop plumbing and routing diagrams
• Electric water pump (EWP) diagnostics and replacement
• High-voltage battery pack cooling manifold schematics
• Coolant air-bleeding procedure using factory scan tools

Torque Specifications

• Electric Powertrain: 88kW motor mounts, reduction gear mounting bolts, casing fasteners
• Chassis & Suspension: MacPherson strut tower bolts, torsion beam axle pivot bolts, wheel hub bolts
• Brakes: Caliper mounting bolts, EPB actuator fasteners, wheel nuts
• Body: Battery pack-to-chassis structural bolts, subframe mounting reinforcement bolts

Who Is This Manual For?

• Professional automotive workshops and electric vehicle specialists
• Independent repair garages and EV technicians
• Mobile mechanics
• 2017 Hyundai IONIQ Electric owners conducting DIY garage maintenance