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

IONIQ 5(NE EV) > 2023 > 70kW+160kW > General Information - Precautions when servicing the high voltage system • Since the electric vehicle contains high voltage battery, if the system or vehicle is handled improperly, it may result in a severe accident such as an electrical short, shock, etc. Therefore, be sure to comply with the following before working on the system. • Be sure not to let anyone other than the person in charge of the work equipped with the protective equipment touch the high voltage-related parts. In order to prevent it, cover any high voltage system not related to the work with an insulation cover. • When working on the high voltage system, be sure to use insulated tools. • Organize and store the removed high voltage parts on an insulated mat to prevent a short circuit. • Check that the voltage between high voltage terminals is 0V or lower. • Install with specified torque when working with high voltage system. • After separating the high voltage cable, insulate the cable by using the insulating tape immediately. • Be careful not to contact between (+) and (-) terminals when disassembling the high voltage cables, bus bars or components related to the high voltage battery. • After disconnecting the high-voltage connector, be sure to remove any coolant around the high-voltage connector as there may be a risk of fire. • All high voltage wiring and connectors are marked in orange. • High-voltage components are labeled with "High Voltage Warning". •High Voltage System Components : Battery System Assembly (BSA), Motor Assembly, Inverter Assembly, High Voltage Junction Block, Power Cable, etc. 1.When servicing a high voltage component, place a "High Voltage Vehicle Warning" sign as shown below to warn others.

2. Metallic object may cause short circuit, leading to personal injury or vehicle damage. Be sure to remove all metallic objects from the body before starting the task. (Metallic objects : watch, ring, and other metallic objects) 3. Before working on the high voltage system, equip yourself with a personal protective equipment to prevent safety- related incidents. (Refer to Battery Control System - "Personal Protective Equipment (PPE)") 4. The high voltage must be shut off prior to inspecting or repairing the high voltage system. (Refer to Battery Control System - "High Voltage Shut-off Procedures")

IONIQ 5(NE EV) > 2023 > 70kW+160kW > General Information - Personal Protective Equipment (PPE) Name Image Purpose Insulated Gloves Used when working with high voltage. [Insulation Performance : 1000 V / 300 A or Greater] Insulated Boots Used when working with high voltage. Insulated Suit Insulated Safety Helmet Protective Goggles Wear in the Following Cases • Installing, removing, or inspecting the high voltage battery terminal or wiring which may cause a spark • Work on the high voltage battery system assembly (BSA)

Face Protection Insulated Mat Organize and store the removed high voltage parts on an insulated mat to prevent any electric shock accident. Insulated Cover Cover the high voltage parts with an insulated cover to prevent any safety-related accidents of a person not equipped with the protective equipment. Warning Tape Place around the vehicle to keep people away from the site in order to prevent any accident during the work. - Personal Protective Equipment (PPE) Inspection • Check to see if insulated boots, insulated suit, insulated helmet, and safety guards are not torn or damaged. • Check to see if the insulated gloves are not torn or damaged. • Be sure to wear fully dried insulated gloves.

① Fold the insulated gloves as shown above. ② Fold 3 to 4 more times to prevent air discharge. ③ Check for any torn or damaged areas.

IONIQ 5(NE EV) > 2023 > 70kW+160kW > General Information 12345 - Precautions for handling Vehicles involved in Accident Preparations when servicing the vehicle involved in an accident • Personal Protective Equipment (PPE) (Refer to Battery Control System - "Personal Protective Equipment (PPE)") • Boric Acid Powder or Solution • Carbon Dioxide Fire Extinguisher or Other Fire Extinguisher • Towel for cleaning electrolyte • Vinyl Tape (for insulating terminal) • Megohm Tester (for checking high voltage insulation resistance) Precautions when handling the vehicle involved in an accident • Be sure to wear Personal Protective Equipment (PPE) • Never touch the power cable where the insulating coating has been peeled off. • If the vehicle is flooded, never approach to the parts with high voltage. If unavoidable, move the vehicle to a safe place before taking action. • Gas is hydrogen and alkaline vapor. If indoor leakage occurs, ventilate the area immediately and evacuate to a safe place. • If there is a skin contact with leaked liquid, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution. • To cut off the high voltage, refer to "High Voltage Shut-off Procedure." (Refer to Battery Control System - "High Voltage Shut-off Procedures") Precaution for vehicle fire If small scale fire occurs, use an extinguisher for electrical fire (ABC or BC) to extinguish. • If the fire has not been put down in early stage, escape to a safe place and keep people out of the vehicle. • Call fire station and report that the vehicle is on fire. Follow the instruction guided by the fire station. • If it is difficult to supress the fire, promptly move to safe place and wait until the rescue arrives. • The fire on the drive motor battery at the bottom of the vehicle requires constant supply of a large volume of water for fire extinguishment. It is difficult to extinguish the fire if there are not enough water or a proper fire extinguisher. Approaching the vehicle may lead to serious injury such as electrical shock. Inspection by the type of accident 1. After the exterior inspection, determine whether the car requires a general repair or a repair specified for car involved in accident. 2. Comply with the repair procedure by DTC code for a general repair. 3. Proceed with the following repair procedure when repairing vehicles involved in accidents. (1) Electrical accident –Overcharging/Overdischarging : Battery Over Voltage (P0DE7)/Under Voltage (P0DE6) Code Display (refer to the DTC Diagnosis Guide) – Short Circuit : High voltage fuse disconnection-related diagnosis (P1B77, P1B25) code display (refer to DTC Diagnosis Guide) (2) Fire Accidents Type Steps to inspect IResults Remedy Fire caught on the area without High Voltage Battery 1. Exterior Inspection (Deformation, rust, wiring sheath, smell and connector) Damage of High Voltage Battery Insulate or wrap the insulator after removing the high voltage battery 2. Measure the high voltage battery insulate resistance after shutting off the high voltage. Breakdown of High Voltage Battery Insulation

(Refer to High Voltage Battery System - "Isolation Resistance Inspection") 3. Check to see if the main fuse is disconnected Disconnection of Main fuse Replace the main fuse (Refer to High Voltage Battery Control System - "Main Fuse") 4. Check to see if the High Voltage Main Relay is welded Welding of High Voltage Main Relay Replace the Power Relay Assembly (PRA) (Refer to High Voltage Battery Control System - "Power Relay Assembly (PRA)") 5. Check for other part failure Other part failure Replace the other part 6. Check the DTC code of the Battery Management Unit (BMU) DTC occurred Follow the DTC inspection guide repair procedure Fire caught on the area with High Voltage Battery 1. Exterior Inspection (Deformation, rust, wiring sheath, smell and connector) Damage of High Voltage Battery Insulate or wrap the insulator after removing the high voltage battery 2. High Voltage Battery Exterior Damage Inspection High Voltage Battery Exterior Damage(Heat marks, soot, etc.) After removing the high voltage battery, follow the high voltage battery disposal procedure 3. Measure the high voltage battery insulate resistance after shutting off the high voltage. Breakdown of High Voltage Battery Insulation Insulate or wrap the insulator after removing the high voltage battery (Refer to High Voltage Battery System - "Isolation Resistance Inspection") 4. Check to see if the main fuse is disconnected Disconnection of Main fuse Replace the main fuse (Refer to High Voltage Battery Control System - "Main Fuse") 5. Check to see if the High Voltage Main Relay is welded Welding of High Voltage Main Relay Replace the Power Relay Assembly (PRA) (Refer to High Voltage Battery Control System - "Power Relay Assembly (PRA)") 6. Check for other part failure Other part failure Replace the other part 7. Check the DTC code of the Battery Management Unit (BMU) DTC occurred Follow the DTC inspection guide repair procedure (3) Car Accidents • If it is difficult to access the high voltage battery due to the vehicle damage, amputate or deform the vehicle body to access the battery for inspection and repair. While cutting or deforming the vehicle body, be careful not to damage the high voltage system. • If the trouble codes do not appear and the exterior look of the battery is okay, do not replace the high voltage battery. (However, if the vehicle is severely damaged and requires a scrap, discard the battery if necessary) Steps to inspect Results Remedy

1. Exterior Inspection (Deformation, rust, wiring sheath, smell and connector) Damage of High Voltage Battery Insulate it or wrap the insulator after removing the high voltage battery 2. Measure the high voltage battery insulate resistance after shutting off the high voltage. (Refer to High Voltage Battery System - "Isolation Resistance Inspection") Breakdown of High Voltage Battery Insulation 3. Check to see if the main fuse is disconnected (Refer to High Voltage Battery Control System - "Main Fuse") Disconnection of Main fuse Replace the main fuse 4. Check to see if the High Voltage Main Relay is welded (Refer to High Voltage Battery Control System - "Power Relay Assembly (PRA)") Welding of High Voltage Main Relay Replace the Power Relay Assembly (PRA) 5. Check for other part failure Other part failure Replace the other part 6. Check the DTC code of the Battery Management Unit (BMU DTC occurred Follow the DTC inspection guide repair procedure (4) Flooding Accidents • If more than half of the vehicle is flooded, do not access any high voltage related parts such as high voltage cut-off switch. Always move the vehicle to a safe area before taking any measures. Type Steps to inspect Results Remedy Flooded area without High Voltage Battery 1. Exterior Inspection (Deformation, rust, wiring sheath, smell and connector) Damage of High Voltage Battery Insulate or wrap the insulator after removing the high voltage battery 2. Measure the high voltage battery insulate resistance after shutting off the high voltage. Breakdown of High Voltage Battery Insulation (Refer to High Voltage Battery System - "Isolation Resistance Inspection") 3. Check to see if the main fuse is disconnected Disconnection of Main fuse Replace the main fuse (Refer to High Voltage Battery Control System - "Main Fuse") 4. Check to see if the High Voltage Main Relay is welded Welding of High Voltage Main Relay Replace the Power Relay Assembly (PRA) (Refer to High Voltage Battery Control System - "Power Relay Assembly (PRA)") 5. Check for other part failure Other part failure Replace the other part 6. Check the DTC code of the Battery Management Unit (BMU) DTC occurred Follow the DTC inspection guide repair procedure Flooded area with High Voltage Battery 1. Exterior Inspection (Deformation, rust, wiring sheath, smell and connector) Measures must be taken regardless of the inspection results Insulate or wrap the insulator after removing the high voltage battery 2. High Voltage Battery Exterior Damage Inspection 3. Measure the high voltage battery insulate resistance after shutting off the high voltage.

(Refer to High Voltage Battery System - "Isolation Resistance Inspection") 4. Check to see if the main fuse is disconnected (Refer to High Voltage Battery Control System - "Main Fuse") 5. Check to see if the High Voltage Main Relay is welded (Refer to High Voltage Battery Control System - "Power Relay Assembly (PRA)") 6. Check for other part failure 7. Check the DTC code of the Battery Management Unit (BMU)

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

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