This 2023 Hyundai KONA Electric (OS EV) 150kW Service and Repair Manual Covers

High-Voltage Electric Drive System

• 150kW Permanent Magnet Synchronous Motor (PMSM)
• Single-speed reduction gear
• High-voltage lithium-ion polymer battery
• Battery Management System (BMS)
• Electric Power Control Unit (EPCU)
• Inverter system diagnostics
• DC-DC converter (LDC)
• On-Board Charger (OBC)
• High-voltage junction box
• Power relay assembly (PRA)
• High-voltage cable inspection and repair
• Charging port servicing
• High-voltage safety plug procedures
• High-voltage cut-off procedures

Battery & Charging System

• AC charging system diagnostics
• DC fast charging system
• Battery cooling system
• Battery temperature sensor diagnostics
• Cell voltage monitoring
• Battery balancing procedures
• State of Charge (SOC) diagnostics
• State of Health (SOH) testing
• Charging communication diagnostics
• Battery replacement procedures

Chassis & Suspension

• MacPherson strut front suspension
• Multi-link rear suspension
• Motor Driven Power Steering (MDPS)
• Steering rack inspection
• Wheel alignment specifications
• Wheel bearing replacement
• Shock absorber servicing
• Suspension bushings
• Stabilizer bar inspection

Braking Systems

• Regenerative braking system
• Anti-lock Braking System (ABS)
• Electronic Stability Control (ESC)
• Electronic Brake-force Distribution (EBD)
• Brake hydraulic system servicing
• Electronic Parking Brake (EPB)
• Brake booster diagnostics
• Brake pad and rotor replacement

Electrical & Wiring

• Complete factory wiring diagrams
• Battery Management System (BMS)
• Vehicle Control Unit (VCU)
• Body Control Module (BCM)
• CAN Bus communication diagnostics
• Charging system diagnostics
• 12-volt auxiliary battery servicing
• Smart Key and immobilizer system
• Lighting system diagnostics
• Instrument cluster servicing
• Infotainment and navigation system diagnostics
• Power windows and door lock diagnostics

Air Conditioning & HVAC

• Heat pump system (where equipped)
• Electric air conditioning compressor
• HVAC control module diagnostics
• Refrigerant recovery and charging procedures
• Cabin heater servicing
• Blower motor servicing
• Cabin air filter replacement

Body & Interior

• Interior trim removal and installation
• Exterior body panel repairs
• Front and rear bumper removal
• Door adjustment procedures
• Tailgate servicing
• Power mirror servicing
• Seat removal and installation
• Airbag (SRS) diagnostics
• Seat belt pretensioner servicing

Hyundai SmartSense & Driver Assistance

• Forward Collision-Avoidance Assist (FCA)
• Lane Keeping Assist (LKA)
• Lane Following Assist (LFA)
• Blind-Spot Collision Warning (BCW)
• Rear Cross-Traffic Collision Warning (RCCW)
• Smart Cruise Control (SCC)
• Driver Attention Warning (DAW)
• Parking Distance Warning (PDW)
• Camera and radar calibration procedures

Diagnostics & Troubleshooting

• Complete Diagnostic Trouble Code (DTC) lookup
• High-voltage system diagnostics
• Active test procedures
• Sensor inspection and testing
• Actuator testing
• ECU initialization
• Scan tool diagnostics
• Electrical troubleshooting workflows
• Factory service specifications

Common Error Codes Covered

This manual provides complete diagnostic and repair procedures for Hyundai manufacturer-specific fault codes.

Electric Drive & Battery Codes

• P0A80 – Replace Hybrid/EV Battery Pack
• P0AA6 – High Voltage System Isolation Fault
• P1AA6 – Battery Energy Control System Fault
• P1B77 – High Voltage Battery Temperature Sensor Fault
• P1C2D – On-Board Charger Performance Fault

Charging System Codes

• P0D26 – Battery Charger Performance
• P1A10 – Charging Communication Error
• P1A6F – High Voltage Interlock Circuit Fault

ABS & Chassis Codes

• C1206 – Front Wheel Speed Sensor Signal Error
• C1210 – Wheel Speed Sensor Circuit Fault
• C2402 – Motor Circuit Failure

Network Communication Codes

• U0001 – High-Speed CAN Communication Bus Fault
• U0100 – Lost Communication with Vehicle Control Module

Body Control Codes

• B1102 – Driver Airbag Circuit Fault
• B1620 – Smart Key Communication Error

And thousands of additional diagnostic codes, wiring diagrams, testing procedures, repair specifications, maintenance schedules, and service procedures.

Who Is This Manual For?

This manual is ideal for:

• Hyundai dealership technicians
• Electric vehicle service specialists
• Professional automotive workshops
• Independent EV repair garages
• Mobile mechanics
• Automotive students
• Fleet maintenance teams
• DIY electric vehicle owners

If you are diagnosing, servicing, maintaining, or repairing the 2023 Hyundai KONA Electric (OS EV) 150kW, this factory workshop manual provides the detailed procedures, specifications, wiring diagrams, high-voltage safety instructions, and troubleshooting information needed to perform the job correctly.