2022 Hyundai SONATA Hybrid (DN8 HEV) G 2.0 GDI HEV Service and Repair Manual

This 2022 Hyundai SONATA Hybrid (DN8 HEV) G 2.0 GDI HEV Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Component removal and installation
• Repair and overhaul procedures
• Technical specifications
• Factory maintenance schedules
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information
• Diagnostic flow charts

Engine Options

• 2.0L Smartstream GDi Hybrid Inline-4 Petrol (G 2.0 GDI HEV)

Transmission Options

• 6-speed Hybrid Automatic Transmission (6AT HEV with Active Shift Control)

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Timing chain inspection and replacement
• Gasoline Direct Injection (GDI) diagnostics
• Hybrid engine management diagnostics
• Cooling system repairs
• Lubrication system servicing
• Intake and exhaust system servicing
• Emissions system diagnostics
• Hybrid automatic transmission servicing
• Hybrid transmission diagnostics
• Driveshaft servicing
• CV joint inspection and repair

Powertrain Covered

• Smartstream G2.0 GDi HEV engine
• Permanent magnet synchronous electric drive motor
• Lithium-ion polymer high-voltage battery
• Hybrid Control Unit (HCU)
• Battery Management System (BMS)
• Hybrid starter-generator
• 6-speed hybrid automatic transmission
• Inverter and motor control system
• DC-DC converter
• Regenerative braking system
• High-voltage power distribution system

Electric Drivetrain Repair Coverage

• High-voltage battery diagnostics
• Battery Management System diagnostics
• Hybrid Control Unit diagnostics
• Electric motor diagnostics
• Inverter diagnostics
• High-voltage cable inspection
• Motor resolver testing
• DC-DC converter diagnostics
• Regenerative braking diagnostics
• High-voltage system isolation testing
• Battery cooling system servicing

ADAS and Safety Technologies

• Forward Collision-Avoidance Assist diagnostics
• Lane Keeping Assist diagnostics
• Lane Following Assist diagnostics
• Blind-Spot Collision-Avoidance Assist diagnostics
• Rear Cross-Traffic Collision-Avoidance Assist diagnostics
• Smart Cruise Control calibration
• Driver Attention Warning diagnostics
• Front radar calibration
• Front camera alignment
• Parking sensor diagnostics

Hybrid and EV Technologies

• High-voltage battery diagnostics
• Battery Management System diagnostics
• Hybrid Control Unit diagnostics
• Electric motor diagnostics
• Regenerative braking diagnostics
• Hybrid transmission diagnostics
• DC-DC converter diagnostics
• Hybrid charging system diagnostics
• Energy management system diagnostics

Chassis, Steering and Suspension

• Front MacPherson strut suspension servicing
• Rear multi-link suspension servicing
• Electronic power steering diagnostics
• Steering column servicing
• Shock absorber replacement
• Coil spring inspection
• Wheel bearing servicing
• Stabiliser bar servicing
• Wheel alignment specifications

Braking Systems

• ABS diagnostics
• Electronic Stability Control diagnostics
• Traction Control System diagnostics
• Electronic Parking Brake servicing
• Regenerative braking diagnostics
• Brake hydraulic system bleeding
• Disc brake servicing
• Wheel speed sensor testing

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Hybrid control system wiring
• High-voltage system wiring
• Battery Management System wiring
• CAN communication network diagnostics
• Engine management system
• Charging system diagnostics
• Starting system diagnostics
• Smart key system
• Immobiliser diagnostics
• Instrument cluster diagnostics
• Lighting system diagnostics
• Infotainment wiring
• Power window diagnostics
• Power mirror diagnostics
• Central locking diagnostics

Air Conditioning and HVAC

• Dual-zone automatic climate control diagnostics
• Electric A/C compressor diagnostics
• Refrigerant system servicing
• HVAC control module diagnostics
• Blower motor servicing
• Air distribution system servicing
• Cabin air quality system diagnostics

Body, Interior and Restraint Systems

• Body panel removal and installation
• Interior trim servicing
• Dashboard removal procedures
• Power seat servicing
• Smart key diagnostics
• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Rain sensor diagnostics
• Power boot servicing (where equipped)

Diagnostics and Troubleshooting

• Factory diagnostic flow charts
• Symptom-based troubleshooting
• Hybrid system diagnostics
• High-voltage safety procedures
• Scan tool diagnostics
• Sensor testing procedures
• Actuator testing
• CAN communication diagnostics
• Electrical fault isolation
• ECU programming procedures

Common Error Codes Covered

Engine Codes

• P0017 — Crankshaft Position–Camshaft Position Correlation (Bank 1 Sensor B)
• P0106 — Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance
• P0191 — Fuel Rail Pressure Sensor Range/Performance
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0420 — Catalyst System Efficiency Below Threshold (Bank 1)

EV Powertrain Codes

• P0A0D — High Voltage System Interlock Circuit High
• P0A1F — Hybrid Powertrain Control Module
• P0A7F — Hybrid Battery Pack Deterioration
• P0A92 — Hybrid Motor Performance
• P0AC4 — Hybrid Powertrain Control Module Requested MIL Illumination

Charging System Codes

• P0A08 — DC/DC Converter Status Circuit
• P1B77 — High-Voltage Battery System Performance

ABS and Chassis Codes

• C1208 — Rear Right Wheel Speed Sensor Circuit Fault
• C1210 — Rear Left Wheel Speed Sensor Signal Fault
• C1260 — Steering Angle Sensor Calibration Required

Network Communication Codes

• U0100 — Lost Communication With Engine Control Module (ECM/PCM)
• U0293 — Lost Communication With Hybrid Powertrain Control Module

Body Control Codes

• B1326 — Battery Voltage Low
• B1602 — Smart Key Authentication Failure

ADAS Codes

• C1604 — Front Camera Calibration Required
• C1620 — Front Radar Sensor Alignment Required

Plus many other codes included in the manual.

Fuse Box Diagram

• Engine compartment fuse box layout
• Interior fuse box layout
• High-voltage fuse locations
• Hybrid system fuse identification
• Relay locations
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Hybrid powertrain system
• High-voltage battery system
• Battery Management System
• Inverter system
• Electric motor system
• Hybrid transmission
• Engine management system
• ABS/ESC system
• Electronic parking brake
• ADAS systems
• Air conditioning system
• SRS airbag system
• Instrument cluster
• Smart key system
• CAN communication network
• Lighting system
• Infotainment system
• Power windows
• Central locking

Serpentine Belt and Timing System Information

• Accessory drive belt routing
• Serpentine belt inspection procedures
• Belt replacement procedures
• Timing chain inspection
• Timing chain replacement procedures
• Timing chain alignment specifications

Torque Specifications

• Engine fastener torque values
• Cylinder head torque specifications
• Main bearing torque values
• Connecting rod torque values
• Hybrid transmission torque values
• Suspension torque specifications
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications
• High-voltage component mounting torque specifications

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Hybrid transmission fluid servicing
• Engine coolant replacement
• Inverter coolant servicing
• Brake fluid replacement
• Spark plug replacement
• Engine air filter replacement
• Cabin air filter replacement
• Serpentine belt inspection
• High-voltage battery inspection
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Hybrid vehicle repair specialists
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions