2023 Hyundai IONIQ 5 Service Repair Manual (NE EV 70kW+160kW)

Engine and Drivetrain

• 70kW (94 hp) Permanent-Magnet Synchronous Motor (PMSM) – Front Axle Motor
• 160kW (215 hp) Permanent-Magnet Synchronous Motor (PMSM) – Rear Axle Motor
• 230kW (320 hp / 325 PS) Combined Output – Electronic All-Wheel Drive (AWD / HTRAC)

• Complete dual electric motor assembly (Front & Rear) diagnostics and replacement
• High-Voltage (HV) battery system teardown and isolation procedures
• Front and rear single-speed reduction gear transmission rebuilding
• EV AWD Disconnector Actuator System (DAS) diagnostics and servicing
• Dual motor/inverter liquid cooling system loop repairs
• Power Electric (PE) system insulation testing and safety guidelines
• High-voltage interlock loop (HVIL) tracking and repairs
• E-GMP dedicated EV platform dual-transaxle servicing
• Front and rear Integrated Drive Axle (IDA) and constant velocity (CV) axle shaft servicing

Chassis and Suspension

• Front suspension repair procedures (MacPherson strut adapted for AWD)
• Rear suspension repair procedures (Multi-link independent suspension)
• Motor-Driven Power Steering (MDPS) rack diagnostics and calibration
• Wheel alignment specifications and AWD geometry data
• Integrated front and rear wheel bearing and hub replacement
• Suspension component bushing and mounting bolt inspection

Braking Systems

• Hydraulic braking system
• Anti-lock Braking System (ABS)
• Electronic Brakeforce Distribution (EBD)
• Electronic Stability Control (ESC)
• Integrated Brake Actuation (IBA) / Smart Regenerative Braking system
• Brake Assist System (BAS)
• Traction Control System (TCS)
• Electronic parking brake (EPB) servicing and pad replacement mode
• Brake component inspection, disc/pad specifications, and dual-axle calipers
• Electronic brake bleeding procedures (DOT 4 specification)

Electrical and Wiring

• Complete factory 12V and dual-motor high-voltage wiring diagrams
• Low-voltage 12V battery and Low DC-DC Converter (LDC) charging diagnostics
• 77.4 kWh Long Range Lithium-ion polymer battery management system (BMS)
• 800V high-voltage architecture distribution schematics
• Multi-charging system (400V/800V boost converter) diagnostics
• Junction block and smart fuse box diagrams
• Integrated Central Control Unit (ICCU) diagnostics
• Vehicle-to-load (V2L) power management systems (internal and external ports)
• CAN Bus, LIN Bus, and Ethernet communication diagnostics
• Full LED lighting system diagnostics (Parametric Pixel design)
• Dual 12.3-inch integrated instrument cluster and infotainment diagnostics
• OTA (Over-the-Air) module and Bluelink telematics routing

Air Conditioning and HVAC

• High-efficiency heat pump system diagnostics (standard on AWD configurations)
• Automatic dual-zone climate control diagnostics
• High-voltage electric A/C compressor replacement
• Positive Temperature Coefficient (PTC) cabin heater diagnostics
• Refrigerant servicing procedures (R-1234yf system)
• Cabin air filter replacement and air distribution actuator diagnostics
• HVAC control module diagnostics

Body and Interior

• Eco-processed interior trim and seat assembly removal
• Integrated digital dashboard assembly removal procedures
• Flush-mounted motorized exterior door lock and window repairs
• Aerodynamic active air flap (AAF) mechanism servicing
• Parametric pixel LED lighting and light bar repairs
• Central locking and digital key/proximity entry diagnostics
• 10-way power relaxation comfort seat servicing
• Sunroof or Vision Roof assembly servicing
• Hyundai SmartSense advanced driver assistance system (ADAS) recalibration
• Supplemental Restraint System (SRS Airbag) diagnostics
• Occupant classification system (OCS) calibration

Diagnostics and Troubleshooting

• Diagnostic Trouble Code (DTC) lookup
• Factory diagnostic workflows
• Global Diagnostic System (GDS-M) scan tool procedures
• High-voltage insulation resistance live data interpretation
• Battery cell voltage balancing and health metrics testing
• Component testing procedures and resistance specifications
• Control module replacement coding
• Wiring connector identification and pinouts
• ADAS forward camera, blind spot radar, and surround view calibration procedures

Common Error Codes Covered

Electric Motor and Inverter Codes

• P0A78: Drive Motor “A” Inverter Performance (Rear Motor Inverter)
• P0A7A: Generator Inverter Performance (Front Motor Inverter)
• P0C17: Drive Motor “A” Position Sensor Not Learnt
• P0A1D: Motor Control Module Malfunction
• P1A0C: AWD Disconnector Actuator (DAS) Signal Malfunction

High-Voltage Battery and Charging Codes

• P0AA6: Hybrid/EV Battery System Isolation Fault
• P1A9C: Battery Management System (BMS) Internal Malfunction
• P0AC4: Hybrid/EV Powertrain Control Module Requested MIL Illumination
• P1C26: ICCU (Integrated Central Control Unit) DC-DC Converter Error

ABS and Chassis Codes

• C1202: ABS/ESC Wheel Speed Sensor Signal Malfunction
• C1613: CAN Time-out Main Body ECU
• C2402: Motor-Driven Power Steering (MDPS) Motor Error

Network Communication Codes

• U0100: Lost Communication with Engine/Powertrain Control Module
• U0111: Lost Communication with Battery Energy Control Module
• U0293: Lost Communication with Hybrid/EV Powertrain Control Module
• U1104: Controller Area Network (CAN) Bus Communication Disruption

Body Control Codes

• B1603: CAN Communication Circuit Error (Smart Junction Box)
• B2810: Flush Door Handle Actuator Malfunction

Fuse Box Diagram

• Front trunk (Frunk) motor compartment fuse box (AWD layout)
• Passenger compartment smart junction box (Lower left driver kick panel)
• Fuse amperage ratings and circuit protection limits
• Relay locations
• Circuit identification
• High-voltage safety plug / disconnect location

Wiring Diagrams

• Dual Power Electric (PE) system management
• 12V Battery charging and low-voltage conversion
• High-voltage distribution and fast-charging interfaces
• ABS / ESC / Regenerative braking loops
• Heat pump and interior climate control systems
• SRS Airbag restraint modules
• Next-generation infotainment and premium audio routing
• SmartSense ADAS radar/camera networking
• Vehicle-to-load (V2L) electrical distribution

Cooling System Routing Diagrams

• Liquid-cooling loop routing for the PE (Power Electric) dual-motor system
• High-voltage battery assembly thermal management routing
• Coolant type and dual-system capacity specifications
• Coolant air-bleeding procedures using diagnostic tools

Torque Specifications

• Front and rear electric motor mount fasteners
• Reduction gear transaxle housing and case bolts (Front & Rear units)
• High-voltage battery pack mounting frame bolts
• Subframe structural fasteners
• Suspension arms, struts, and links to chassis
• Steering gear and tie rod connections
• Brake calipers, carrier brackets, and wheel hub assemblies
• Wheel lug nuts
• Front and rear CV axle nut tension settings
• Interior and exterior aerodynamic trim fasteners

This manual is ideal for:

• Professional automotive workshops
• Independent EV repair garages
• Certified electric vehicle mechanics
• Fleet maintenance technicians
• Vehicle owners performing DIY repairs
• Automotive engineering and training institutions