2020 Hyundai IONIQ Plug-in Hybrid 1.6L Service and Repair Manual

Engine and Drivetrain

• Kappa 1.6L GDI (Gamma) 4-Cylinder Engine (Inline Atkinson-cycle petrol engine)
• Permanent Magnet Synchronous Motor (PMSM) rated at 44.5 kW (60 hp)
• 8.9 kWh Lithium-ion Polymer High-Voltage Battery Pack (360V System)

• Complete engine overhaul and mechanical disassembly procedures
• Gasoline Direct Injection (GDI) fuel system diagnostics and high-pressure rail servicing
• Distributorless electronic ignition system coil-on-plug service procedures
• High-voltage (HV) battery cooling fan servicing and duct inspection
• Engine cooling system and specialized hybrid inverter/power electronics cooling circuits
• Lubrication system and variable oil pump servicing
• Exhaust and dual-stage emissions control diagnostics
• Timing chain inspection, variable valve timing (D-CVVT) setup, and replacement intervals
• D6KF1 6-speed EcoShift Dual-Clutch Transmission (DCT) diagnostics, clutch calibration, and rebuilding
• Hybrid Power Control Unit (HPCU) / Inverter servicing and cooling manifold repairs
• Front-Wheel Drive (FWD) axle shafts and constant velocity (CV) joint boot replacement

Chassis and Suspension

• Front MacPherson strut independent suspension repair procedures
• Rear multi-link independent suspension (specifically lightened for PHEV battery weight distribution)
• Motor Driven Power Steering (MDPS) rack-and-pinion diagnostics and electronic calibration
• Wheel alignment specifications (including rear toe/camber adjustments for hybrid tracks)
• Front and rear wheel bearing/hub assembly replacement
• Anti-roll bar and control arm bushing inspections

Braking Systems

• Hydraulic braking system with Integrated Brake Actuation Unit (IBAU)
• Four-wheel Anti-lock Braking System (ABS) and Electronic Brakeforce Distribution (EBD)
• Electronic Stability Control (ESC) and Vehicle Stability Management (VSM)
• Regenerative Braking System calibration via steering wheel paddle shifters
• Electronic Parking Brake (EPB) servicing, actuator replacement, and workshop pad replacement mode
• Brake component inspection, pad thickness tolerances, and rotor machining limits
• Specialized hybrid brake bleeding procedures requiring diagnostic scan tools

Electrical and Wiring

• Complete factory wiring diagrams with ground distributions and connector layouts
• 12V Auxiliary battery integration (integrated into the high-voltage pack for the 2020 refresh) with Battery Management System (BMS) diagnostics
• High-Voltage safety circuit path, High-Voltage interlock loop (HVIL), and manual safety plug disconnect location
• Power distribution schematics and Smart Junction Box (SJB) diagrams
• Engine Control Module (ECM) and Hybrid Control Module (HCM) diagnostics
• Controller Area Network (CAN Bus) and Local Interconnect Network (LIN Bus) multiplex communication architecture
• LED headlamp, Daytime Running Lamps (DRL), and automatic high-beam assist diagnostics
• Supervision instrument cluster servicing, EV/HEV mode display diagnostics, and service interval resets
• BlueLink Gen 5 Infotainment systems (8-inch or 10.25-inch touchscreens)
• Power windows, central locking, and Smart Key keyless entry systems

Air Conditioning and HVAC

• Climate Control Module (CCM) and high-voltage PTC cabin heater diagnostics
• Dual-zone automatic climate control diagnostics and blend door actuator calibration
• High-voltage Electric Air Conditioning Compressor replacement (runs off the 360V pack)
• R-1234yf refrigerant servicing procedures, specifications, and oil compatibility safety warnings
• Evaporator core, heater core, and cabin pollen filter replacement guidelines

Body and Interior

• High-strength steel structural body repair and panel bonding specifications
• Interior trim, console, and door panel removal/installation
• Crash pad/dashboard removal procedures for HVAC access
• Exterior aerodynamic underbody shield layouts and bumper replacement
• Power sunroof tracking, alignment, and drain tube cleaning
• Supplemental Restraint System (SRS) airbag component mapping, clock spring replacement, and sensor diagnostics
• Occupant Classification System (OCS) weight sensor zero-point calibration

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup index for Powertrain, Chassis, Body, and U-Network codes
• Global Diagnostic System (GDS-Mobile) scan tool connection workflows
• High-voltage system insulation resistance testing using a megohmmeter
• Live data parameter identification (PID) data streams for individual cell monitoring
• Hybrid system resolver calibration and automatic motor tuning
• Connector pinouts with voltage/resistance reference values

Common Error Codes Covered

Engine and Hybrid Powertrain Codes

• P0A0D: High Voltage System Interlock Circuit High
• P0300: Random/Multiple Cylinder Misfire Detected
• P0128: Coolant Thermostat Malfunction (Engine Coolant Temperature below thermostat regulating temperature)
• P1B70: High Voltage Battery Low Voltage Fault
• P0456: Evaporative Emission System Leak Detected (Very Small Leak)

Transmission Codes

• P0700: Transmission Control System Malfunction (TCM Requesting MIL)
• P0841: Transmission Fluid Pressure Sensor/Switch “A” Circuit Range/Performance

ABS and Chassis Codes

• C1202: Wheel Speed Sensor Rear-Left Invalid/No Signal
• C1612: Lost Communication with TCM (Transmission Control Module)
• C2402: ABS/ESC Motor Electrical Fault

Network Communication Codes

• U0100: Lost Communication with ECM/PCM
• U0110: Lost Communication with Drive Motor Control Module
• U0293: Lost Communication with Hybrid Powertrain Control Module

Body Control Codes

• B1346: Airbag Driver Resistance High (Clock Spring/Driver Airbag Module circuit)
• B1603: CAN Communication Circuit Error – Body Control Module

Fuse Box Diagram

• Engine Compartment Fuse Box (including High-Amperage Multi-fuses for Power Electronics)
• Passenger Compartment Fuse Panel (located behind the lower driver-side dashboard cover)
• High-Voltage Safety Switch / Fuse block assembly (at the high-voltage pack)
• Fuse amperage ratings and structural types (Micro2, Micro3, Multi-fuse formats)
• Relay maps for cooling fans, main power relays, and auxiliary systems

Wiring Diagrams

• 1.6L GDI engine control system and electronic throttle actuation
• Hybrid Power Control Unit (HPCU) gate drive and inverter routing
• Battery Management System (BMS) cell balancing lines
• Smart Cruise Control (SCC) radar and front multi-purpose camera networks
• Virtual Engine Sound System (VESS) artificial noise generator circuit
• 6-Speaker standard or premium 8-Speaker audio architecture

Serpentine Belt Routing Diagrams

• Hybrid Starter Generator (HSG) accessory drive belt routing diagram
• Belt tension check specifications using frequency or deflection tools
• HSG belt automatic tensioner assembly replacement instructions
• Replacement intervals for heavy-duty hybrid application belts

Torque Specifications

• Engine fasteners: Cylinder head bolts, connecting rods, main bearing caps, flywheel assembly
• Hybrid unit fasteners: Electric motor housing-to-engine case, HPCU mounting plate
• Transmission components: Dual-clutch module fasteners, fluid drain/fill plugs, casing bolts
• Suspension fasteners: Front strut tower nuts, lower control arm ball joints, rear multi-link hub carriers
• Brake assemblies: Caliper anchor bracket bolts, slide pins, hydraulic line unions
• Wheel nuts: Lug nut torque specifications for 16-inch aerodynamic factory alloy wheels

This manual is ideal for:

• Professional automotive workshops specializing in Hybrid and Electric Vehicles (EV/PHEV)
• Independent repair garages and alternative fuel fleet maintenance facilities
• Mobile hybrid technicians and high-voltage diagnostic specialists
• 2020 Hyundai IONIQ PHEV owners performing DIY maintenance and safe electrical work