2020 Hyundai IONIQ Electric 100kW Service and Repair Manual

Electric Powertrain and Drivetrain

• Electric Motor: Maintenance and repair instructions for the 100 kW 134 HP Interior Permanent Magnet Synchronous Motor.
• High-Voltage Battery System: Overhaul, isolation, safety procedures, and individual cell monitoring rules for the upgraded 38.3 kWh Lithium-ion Polymer battery pack 319.4V system.
• Power Electronics: Detailed diagnostics and replacement guides for the Integrated Electric Power Control Unit EPCU, including the Inverter, Low-voltage DC-DC Converter LDC, and Vehicle Control Unit VCU.
• On-Board Charging System: Troubleshooting protocols for the 7.2 kW AC Charger and the Combined Charging System CCS DC Fast Charging Port.
• Cooling System: Specialized servicing for the battery pack liquid-cooling system and electric motor coolant loop.
• Transmission and Reduction Gear: Servicing and teardown procedures for the single-speed direct-drive reduction gearbox.
• Driveshaft and Axle: Constant Velocity CV joint boot replacement, front axles, and hub assemblies.

Chassis and Suspension

• Front MacPherson strut disassembly and replacement.
• Rear coupled torsion beam axle CTBA or specialized multi-link setups optimized for the battery assembly floor footprint.
• Motor-Driven Power Steering MDPS calibration, rack and pinion replacement, and alignment specs.
• Wheel bearing and hub assembly replacement.

Braking Systems

• Integrated Electro-Hydraulic Booster IEHB unit troubleshooting.
• Regenerative Braking System: Diagnostics for steering-wheel-mounted paddle selectors and electronic brake blending calibration.
• Anti-lock Braking System ABS, Electronic Stability Control ESC, and Hill-Start Assist Control HAC diagnostic trees.
• Electronic Parking Brake EPB service mode activation and rear motor-on-caliper pad replacement.
• Brake system pressure bleeding sequences using specialized factory software parameters.

Electrical and Wiring Circuits

• Complete, high-resolution factory wiring schematics with connector pinouts, ground location designations, and splicing diagrams.
• 12V auxiliary battery management, smart-charging logic, and Low-Voltage DC-DC Converter diagnostics.
• High-voltage interlocking loop HVIL circuit paths and safety disconnect terminal locations.
• CAN Bus and LIN Bus Networks: Communication hierarchy maps, gateway module architecture, and diagnostic data stream paths.
• Infotainment and Display: Diagnostic routines for the 10.25-inch high-resolution touchscreen infotainment screen, digital supervision instrument cluster, and Apple CarPlay and Android Auto interfaces.

Air Conditioning and HVAC

• High-voltage Heat Pump System diagnostics and component mappings optimized for cold-weather range management.
• High-voltage electric AC compressor replacement and internal isolation resistance testing.
• Automatic climate control module data parameters, blend door actuator calibration, and cabin microfilter replacement.

Body, Interior, and Safety

• Dashboard and console module removal and installation steps.
• Aluminum and high-strength steel body panel alignment tolerances, bumper removal, and active air flap system diagnostics.
• Supplemental Restraint System SRS airbag component tracking, clockspring replacements, and impact sensor locations.
• Smart Key system, push-button start wiring, and proximity sensor diagnostics.

Diagnostics, Troubleshooting, and Advanced Safety Systems ADAS

• Diagnostic Trouble Code DTC lookup indexes for all hybrid and EV propulsion control modules.
• Scan tool communication steps and live sensor data PID interpretation.
• Hyundai SmartSense ADAS Calibration: Radar and camera alignment protocols for Forward Collision-Avoidance Assist FCA, Lane Keeping Assist LKA, Blind-Spot Collision-Avoidance Assist BCA, and Smart Cruise Control SCC with Stop and Go.

Common Error Codes Covered

Propulsion and Battery Codes

• P1A15: High Voltage Capacitor Precharging Fault
• P3000: EV Control System Malfunction or Battery Management System Communication
• P0A0D: High Voltage System Interlock Circuit High

Braking and Chassis Codes

• C1202: Wheel Speed Sensor Front-Left Circuit Fault
• C1611: CAN Timeout EMS Engine or Motor System
• C2402: Motor Driven Power Steering MDPS Motor Circuit Malfunction

Network Communication Codes

• U0100: Lost Communication with VCU Vehicle Control Unit
• U0111: Lost Communication with Battery Energy Control Module BMS

Body and Climate Control Codes

• B16A2: Airbag Front Impact Sensor Circuit Error
• B1011: Ambient Temperature Sensor Open or Short Circuit

Fuse Box Diagram

• Engine compartment E-Room junction block layout.
• Driver-side lower instrument panel interior fuse compartment.
• High-voltage safety plug disconnect visual reference guides.
• Fuse amperage thresholds, circuit allocation indices, and relay terminal pinouts.

Coolant and Drive Belt Diagrams

• Motor and Inverter auxiliary cooling loop hose routing schematics.
• Battery pack temperature regulation coolant pathway diagrams.
• High-voltage system fluid specifications, internal bleeding sequences, and specialized long-life EV coolant requirements.

Torque Tightening Specifications

• Reduction Gearbox Fasteners: Casing bolts, mount brackets, drain and fill plugs.
• Chassis Fasteners: Front strut tower bolts, lower control arm pins, subframe bolts, and wheel lug nuts.
• Brake Components: Caliper slide guide pins, anchor mounting bracket bolts, brake line fittings.
• High-voltage terminal connection torque requirements to prevent resistive heating and arcing.

This manual is optimized for:

• Professional automotive workshops specializing in electric vehicles EVs.
• Independent repair garages expanding into electric powertrain servicing.
• Certified EV diagnostic technicians and high-voltage platform specialists.
• 2020 Hyundai IONIQ Electric owners performing DIY upkeep or component testing.