This 2019 Hyundai KONA Electric (OS EV) 150kW Service and Repair Manual Covers

High-Voltage Electric Drive System

• 150kW Permanent Magnet Synchronous Motor (PMSM)
• Single-speed reduction gear
• 64kWh lithium-ion polymer high-voltage battery
• Battery Management System (BMS)
• Electronic Power Control Unit (EPCU)
• Inverter diagnostics and servicing
• Power Relay Assembly (PRA)
• High-voltage junction box
• High-voltage wiring harness
• DC-DC Converter (LDC)
• On-Board Charger (OBC)
• Charging port servicing
• High-voltage safety plug procedures
• High-voltage cut-off procedures

Battery & Charging System

• AC Level 1 and Level 2 charging diagnostics
• DC fast charging system
• Battery cooling system
• Battery temperature monitoring
• Cell voltage balancing
• Battery State of Charge (SOC) diagnostics
• Battery State of Health (SOH) testing
• Charging communication diagnostics
• Battery replacement procedures

Chassis & Suspension

• MacPherson strut front suspension
• Multi-link rear suspension
• Motor Driven Power Steering (MDPS)
• Steering rack inspection and repair
• Wheel alignment specifications
• Wheel bearing replacement
• Shock absorber servicing
• Suspension bushings
• Stabilizer bar inspection and replacement

Braking Systems

• Regenerative braking system
• Anti-lock Braking System (ABS)
• Electronic Stability Control (ESC)
• Electronic Brake-force Distribution (EBD)
• Brake hydraulic system servicing
• Electronic Parking Brake (where equipped)
• Brake booster diagnostics
• Brake pad and rotor replacement

Electrical & Wiring

• Complete factory wiring diagrams
• Battery Management System (BMS)
• Vehicle Control Unit (VCU)
• Body Control Module (BCM)
• CAN Bus communication diagnostics
• Charging system diagnostics
• 12V auxiliary battery servicing
• Smart Key and immobilizer system
• Lighting system diagnostics
• Instrument cluster servicing
• Infotainment and navigation system
• Power windows and door lock diagnostics

Air Conditioning & HVAC

• Electric air conditioning compressor
• Heat pump system (where equipped)
• HVAC control module diagnostics
• Refrigerant recovery and charging procedures
• Cabin heater servicing
• Blower motor replacement
• Cabin air filter replacement

Body & Interior

• Interior trim removal and installation
• Exterior body panel repairs
• Front and rear bumper removal
• Door adjustment procedures
• Tailgate servicing
• Power mirror repairs
• Seat removal and installation
• Airbag (SRS) diagnostics
• Seat belt pretensioner servicing

Hyundai SmartSense & Driver Assistance

• Forward Collision-Avoidance Assist (FCA)
• Lane Keeping Assist (LKA)
• Driver Attention Warning (DAW)
• Blind-Spot Collision Warning (where equipped)
• Rear Cross-Traffic Collision Warning (where equipped)
• Smart Cruise Control (where equipped)
• Parking Distance Warning (PDW)
• Rear View Monitor (RVM)
• Camera and radar calibration procedures

Diagnostics & Troubleshooting

• Complete Diagnostic Trouble Code (DTC) lookup
• High-voltage system diagnostics
• Active test procedures
• Battery diagnostics
• Inverter testing
• Sensor inspection and testing
• Actuator testing
• ECU initialization
• Scan tool diagnostics
• Factory service specifications

Common Error Codes Covered

This manual provides complete diagnostic and repair procedures for Hyundai manufacturer-specific fault codes.

Electric Drive & Battery Codes

• P0AA6 – High Voltage System Isolation Fault
• P0A80 – Replace Hybrid/EV Battery Pack
• P1AA6 – Battery Energy Control System Fault
• P1B77 – High Voltage Battery Temperature Sensor Fault
• P1C2D – On-Board Charger Performance Fault

Charging System Codes

• P0D26 – Battery Charger Performance
• P1A10 – Charging Communication Error
• P1A6F – High Voltage Interlock Circuit Fault

ABS & Chassis Codes

• C1206 – Front Wheel Speed Sensor Signal Error
• C1210 – Wheel Speed Sensor Circuit Fault
• C2402 – Motor Circuit Failure

Network Communication Codes

• U0001 – High-Speed CAN Communication Bus Fault
• U0100 – Lost Communication with Vehicle Control Module

Body Control Codes

• B1102 – Driver Airbag Circuit Fault
• B1620 – Smart Key Communication Error

And thousands of additional diagnostic codes, wiring diagrams, testing procedures, repair specifications, maintenance schedules, and service procedures.

Who Is This Manual For?

This manual is ideal for:

• Hyundai dealership technicians
• Electric vehicle service specialists
• Professional automotive workshops
• Independent EV repair garages
• Mobile mechanics
• Automotive students
• Fleet maintenance teams
• DIY electric vehicle owners

If you are diagnosing, servicing, maintaining, or repairing the 2019 Hyundai KONA Electric (OS EV) 150kW, this factory workshop manual provides the detailed procedures, specifications, wiring diagrams, high-voltage safety instructions, and troubleshooting information needed to perform the job correctly.