2021 Hyundai IONIQ Hybrid Service and Repair Manual (AE HEV 1.6L GDI)

Engine and Drivetrain

• 1.6L Kappa GDI 4-Cylinder Engine (G4LE) featuring gasoline direct injection and Atkinson cycle timing
• 32 kW Permanent Magnet Synchronous Motor (PMSM) integrated into the transmission housing

• Complete engine overhaul, mechanical tolerances, and block tear-down procedures
• High-pressure GDI fuel delivery and direct-injection rail diagnostics
• Dual CVVT (Continuously Variable Valve Timing) actuator replacement
• Hybrid cooling system isolation, draining, and refilling procedures (Engine vs. Electronics loops)
• Exhaust Gas Recirculation (EGR) valve cooling and emissions diagnostics
• Timing chain replacement, tensioner setup, and sprocket alignment
• 6-Speed EcoShift Dual-Clutch Transmission (D6KF1) mechanical overhaul procedures
• Dual-clutch assembly replacement and transmission control actuator calibration
• Hybrid Starter-Generator (HSG) belt inspection, tensioning, and replacement
• Front drive axle CV shafts, boots, and differential bearing replacement

Chassis and Suspension

• Front suspension repair procedures
• Rear suspension repair procedures (Multi-link layout optimized for under-seat hybrid battery packaging)
• Steering system diagnostics
• Wheel alignment specifications
• Wheel bearing replacement
• Suspension component inspection

Braking Systems

• Integrated E-Brake (IEB) hydraulic unit assembly and diagnostics
• Regenerative Braking System (RBS) 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 Hybrid Systems

• High-Voltage Safety Disconnect procedures and manual service plug location
• 1.56 kWh Lithium-ion Polymer Battery Pack monitoring, cell balancing, and complete assembly replacement (Located under the rear seat)
• Hybrid Power Control Unit (HPCU) inverter and LDC (Low-voltage DC-DC Converter) diagnostics
• High-voltage orange cabling inspection, routing, and safety isolation testing
• Battery Management System (BMS) live data stream parameters and flashing protocols

Electrical and Wiring

• Complete factory wiring diagrams
• Auxiliary 12V battery system maintenance (Integrated lithium battery pack with Battery Reset functionality)
• Power distribution schematics
• Fuse box diagrams
• Body Control Module (BCM) configuration and central locking logic
• Engine Control Module (ECM) and Hybrid Control Module (HCU) pinpoint testing
• Controller Area Network (CAN-Bus) and Local Interconnect Network (LIN-Bus) topologies
• Lighting system diagnostics
• Instrument cluster servicing
• Factory infotainment systems
• Power windows and door lock diagnostics

Air Conditioning and HVAC

• Climate control diagnostics
• Automatic climate control diagnostics
• Dual-zone climate control servicing
• High-Voltage Electric A/C Compressor diagnosis and isolation procedures
• POEs (Polyolester) non-conductive oil flushing rules to prevent high-voltage isolation breakdown
• Heater system repairs
• 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

Engine and Hybrid Powertrain Codes

• P0300: Random/Multiple Cylinder Misfire Detected
• P1A15: High Voltage Bus Capacitor Discharging Failure
• P1B70: High Voltage Battery State of Charge (SOC) Low Malfunction
• P1B77: High Voltage Battery Precharging Fault
• P0A0D: High Voltage System Isolation Fault / System Interlock Circuit High

Transmission and DCT Codes

• P0700: Transmission Control System (MIL Request)
• P2832: Shift Fork “A” Position Circuit Performance (Dual-Clutch engagement error)
• P2837: Shift Fork “B” Position Circuit Range/Performance
• P1704: Clutch Engagement Sensor 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 ECM
• U0110: Lost Communication With Drive Motor Control Module
• U0298: Lost Communication With DC-to-DC Converter Control Module
• 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

Serpentine Belt and Timing Belt Routing Diagrams

• Hybrid Starter-Generator (HSG) dedicated accessory drive belt routing map
• Automatic HSG tensioner replacement procedures and alignment verification
• Drive belt service replacement intervals and wear inspection specifications

Torque Specifications

• Engine fasteners
• Cylinder head bolts (Torque-plus-angle multi-stage yield procedures)
• Main bearings and connecting rod fasteners
• Hybrid Motor-to-Engine Bell Housing Alignment Bolts
• Dual-Clutch Flywheel and Damper Plate Fasteners
• Transmission components
• Suspension fasteners
• Steering components
• Brake assemblies
• Wheel nuts: 107–127 N·m (79–94 lb-ft)
• High-Voltage Battery Housing Structural Frame Fasteners
• 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