2021 Hyundai IONIQ Electric Service and Repair Manual (AE EV 100kW)

Motor and Drivetrain

• 100 kW Permanent Magnet Synchronous Motor (PMSM) front-mounted electric drive assembly

• Complete electric motor assembly teardown, insulation testing, and mounting repairs
• Motor cooling jacket inspection, draining, and specific low-conductivity coolant refilling
• Single-Speed Reduction Gear Transaxle (Gearbox assembly) overhaul and bearing replacement
• Shift-by-Wire (SBW) electronic selector actuator calibration and diagnostic testing
• Front drive axle CV shafts, outer joints, boots, and differential bearing replacement

Chassis and Suspension

• Front suspension repair procedures
• Rear suspension repair procedures
• Steering system diagnostics
• Wheel alignment specifications
• Wheel bearing replacement
• Suspension component inspection

Braking Systems

• Integrated E-Brake (IEB) electro-hydraulic unit assembly and diagnostics
• Regenerative Braking System (RBS) multi-level adjustable blend control diagnostics
• Four-wheel Anti-lock Braking System (ABS)
• Electronic Stability Control (ESC)
• Electronic Parking Brake (EPB) actuator servicing, pad replacement, and service mode retraction
• Brake component inspection
• Brake bleeding procedures

High-Voltage EV Systems

• High-Voltage Safety Disconnect procedures and manual service plug location
• 38.3 kWh Lithium-ion Polymer Battery Pack monitoring, cell balancing, and complete assembly replacement
• Electric Power Control Unit (EPCU) inverter, MCU (Motor Control Unit), and LDC (Low-voltage DC-DC Converter) diagnostics
• On-Board Charger (OBC) assembly and Combined Charging System (CCS Type 1 / Type 2) AC/DC charging port diagnostics
• High-voltage orange cabling inspection, routing, and safety isolation testing
• Battery Management System (BMS) live data stream parameters and flashing protocols
• Battery thermal management system (active liquid cooling/heating) maintenance

Electrical and Wiring

• Complete factory wiring diagrams
• Auxiliary 12V battery system maintenance and smart charging sensor diagnostics
• Power distribution schematics
• Fuse box diagrams
• Body Control Module (BCM) configuration and central locking logic
• Motor Control Unit (MCU) and Vehicle Control Unit (VCU) pinpoint testing
• Controller Area Network (CAN-Bus) and Local Interconnect Network (LIN-Bus) topologies
• LED headlamp assemblies, leveling motors, and High Beam Assist diagnostics
• 7-inch LCD Supervision instrument cluster servicing
• 10.25-inch Audio Video Navigation (AVN 5.0) Blue Link infotainment architecture
• Power windows and door lock diagnostics

Air Conditioning and HVAC

• Climate control diagnostics
• Automatic climate control diagnostics
• High-Voltage Electric A/C Compressor diagnosis and isolation procedures
• High-efficiency Heat Pump system diagnostics and multi-way electronic valve operation
• POEs (Polyolester) non-conductive oil flushing rules to prevent high-voltage isolation breakdown
• Heater core assembly and Electronic Positive Temperature Coefficient (PTC) high-voltage heater diagnostics
• HVAC control module diagnostics

Body and Interior

• Interior trim removal and installation
• Dashboard removal procedures
• Door and window repairs
• Exterior body component servicing
• Lighting repairs
• Central locking diagnostics
• Sunroof assembly, track alignment, and motor calibration
• Airbag system repairs
• Occupant restraint system servicing

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup
• Factory diagnostic workflows
• Scan tool procedures
• Live data interpretation
• Sensor testing specifications
• Component testing procedures
• Control module diagnostics
• Wiring connector identification
• Connector pinouts

Common Error Codes Covered

Motor and EV Powertrain Codes

• P0A0D: High Voltage System Isolation Fault / System Interlock Circuit High
• P1A15: High Voltage Bus Capacitor Discharging Failure
• P1B70: High Voltage Battery State of Charge (SOC) Low Malfunction
• P1B77: High Voltage Battery Precharging Fault
• P0C90: Drive Motor “A” Inverter Current High / Module Fault

Transmission and Shift-by-Wire Codes

• P0700: Transmission Control System (MIL Request)
• P1C25: Shift-by-Wire Actuator Position Calibration Error
• P1C27: Shift-by-Wire Actuator Motor Voltage Circuit Malfunction

ABS, Chassis, and Brakes Codes

• C1202: Front Wheel Speed Sensor Left Open/Short Circuit
• C2325: Integrated E-Brake (IEB) Motor Voltage Range Fault
• C1613: MDPS (Power Steering) CAN Communication Interrupted
• C2402: Motor Circuit Malfunction – ABS/ESC Pump

Network Communication Codes

• U0100: Lost Communication With VCU/ECM
• U0110: Lost Communication With Drive Motor Control Module / MCU
• U0298: Lost Communication With DC-to-DC Converter Control Module / LDC
• U0146: Lost Communication With Gateway Module

Body and Climate Control Codes

• B1102: Battery Low Voltage (Auxiliary 12V Network)
• B1603: CAN Communication Error – Left Blind Spot Collision Radar
• B2406: Inverter A/C Compressor Internal Controller Error

Fuse Box Diagram

• Engine compartment fuse box
• Passenger compartment fuse panel
• Fuse amperage ratings
• Relay locations
• Circuit identification
• Power distribution diagrams

Wiring Diagrams

• Engine management
• Charging system
• Starting system
• Lighting
• ABS
• Climate control
• Airbags
• Audio and infotainment
• Body electronics

Torque Specifications

• Engine fasteners
• Transmission components
• Suspension fasteners
• Steering components
• Brake assemblies
• Wheel nuts: 107–127 N·m (79–94 lb-ft)
• Body fasteners

This manual is ideal for:

• Professional automotive workshops
• Independent repair garages
• Mobile mechanics
• Automotive technicians
• Vehicle owners performing DIY repairs
• Automotive training institutions