2022 Hyundai IONIQ PHEV Service Repair Manual (AE PHEV 1.6L GDI)

Name: 2022 Hyundai IONIQ PHEV Service Repair Manual (AE PHEV 1.6L GDI)
Brand: New Zealand and Australia Motors

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Price: $57.99

Overview

This factory Service and Repair Manual for the 2022 Hyundai IONIQ Plug-in Hybrid (AE PHEV) provides comprehensive technical specifications, diagnostic procedures, troubleshooting information, and step-by-step repair instructions for all major vehicle systems fitted to this model year.

The manual covers the internal combustion engine, electric motor, hybrid transaxle, high-voltage battery system, suspension, braking systems, electrical networks, climate control, body components, and electronic control modules available on the 2022 Hyundai IONIQ PHEV. It also includes complete factory wiring diagrams, diagnostic procedures, repair illustrations, torque specifications, and manufacturer-approved service procedures.

The manual also covers vehicle-specific technologies such as the High-Voltage Safety Disconnect system, Regenerative Braking System (RBS), Hybrid Power Control Unit (HPCU), 8.9 kWh Lithium-ion Polymer battery pack, 10.25-inch Blue Link infotainment system, and the Hyundai SmartSense advanced safety suites available for this model year.

Whether you are a professional technician, workshop owner, automotive student, or DIY enthusiast, this manual provides the factory information required to diagnose, service, maintain, and repair the 2022 Hyundai IONIQ Plug-in Hybrid.

What you get;

✓ Genuine factory workshop manual
✓ Comprehensive diagnostic procedures
✓ Complete factory wiring diagrams
✓ Covers all factory-installed systems and components
✓ We review every manual to ensure it's genuine and safe for download

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Category: Service and Repair Manuals

Description
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This 2022 Hyundai IONIQ Plug-in Hybrid Service and Repair Manual Covers

Engine and Drivetrain

The manual includes complete repair procedures for:

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

Coverage includes:

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

Coverage includes only the suspension and steering systems fitted to this PHEV chassis:

Front suspension repair procedures
Rear suspension repair procedures (PHEV-specific geometry for battery clearance)
Steering system diagnostics
Wheel alignment specifications
Wheel bearing replacement
Suspension component inspection

Braking Systems

The manual includes repair procedures for all braking systems fitted to the vehicle:

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 using automated diagnostic scan tool routines

High-Voltage Hybrid Systems

Comprehensive safety and service documentation for the plug-in hybrid drivetrain:

High-Voltage Safety Disconnect procedures and manual service plug location
8.9 kWh Lithium-ion Polymer Battery Pack monitoring, cell balancing, and complete assembly replacement
Hybrid Power Control Unit (HPCU) inverter and LDC (Low-voltage DC-DC Converter) diagnostics
On-Board Charger (OBC) assembly and Type 1 AC charging port 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

Coverage includes every factory-installed electrical system available on the vehicle:

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
Engine Control Module (ECM) and Hybrid Control Module (HCU) 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

Coverage includes:

Climate control diagnostics
Automatic climate control diagnostics
Dual-zone climate control servicing
High-Voltage Electric A/C Compressor diagnosis and isolation procedures
Heat pump system diagnostics and multi-way valve operation (where equipped for winter efficiency)
POEs (Polyolester) oil flushing rules to prevent high-voltage isolation breakdown
Heater core assembly and Electronic Positive Temperature Coefficient (PTC) heater diagnostics
HVAC control module diagnostics

Body and Interior

Coverage includes:

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

Diagnostics and Troubleshooting

The manual includes complete manufacturer-approved diagnostic procedures:

Diagnostic Trouble Code (DTC) lookup tables for all vehicle sub-networks
Factory diagnostic workflows
Scan tool procedures
Live data interpretation
Sensor testing specifications
Component testing procedures
Control module diagnostics
Wiring connector identification
Connector pinouts
Hyundai SmartSense Calibration procedures: Forward Collision-Avoidance Assist (FCA), Lane Keeping Assist (LKA), and Smart Cruise Control (SCC) front radar/camera setup

Common Error Codes Covered

This manual includes diagnostic procedures for thousands of Hyundai-specific Diagnostic Trouble Codes (DTCs).

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

Locate every fuse and relay installed on the 2022 Hyundai IONIQ PHEV using complete factory fuse box diagrams.

Coverage includes:

Engine Compartment Junction Block (Powertrain and high-current vehicle modules)
Instrument Panel Fuse Block (Drivers side lower dash panel)
High-Voltage Battery System Main Safety Fuse Block (Integrated into the rear battery housing)
Fuse amperage ratings
Relay locations
Circuit identification
Power distribution diagrams

Wiring Diagrams

The manual includes complete factory wiring diagrams covering every factory-installed electrical circuit available on the vehicle.

Coverage includes systems such as:

G4LE Engine management
Charging system
Starting system
Lighting
ABS
Climate control
Airbags
Audio and infotainment
Body electronics
High-Voltage Hybrid systems
SmartSense Driver Assist System Bus Topologies

Serpentine Belt Routing Diagrams

The manual includes:

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

The manual provides complete factory torque specifications for major vehicle components, including:

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
Steering components
Brake assemblies
Wheel nuts: 107–127 N·m (79–94 lb-ft)
High-Voltage Battery Housing Structural Frame Fasteners

This manual is ideal for:

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

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