2011 Hyundai SONATA Hybrid (YF HEV) G 2.4 HEV Service & Repair Manual

SONATA Hybrid(YF HEV) > 2011 > G 2.4 HEV > General - Safety Precaution This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution. • A caution label for high voltage is attached to the high voltage components. • The color of the high voltage cables and connectors are orange. • Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE). •High Voltage Component: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor, etc. • For your safety when servicing the hybrid vehicle : - Wear Personal Protection Equipment (Insulation Gloves and Safety Glasses). - Do not carry any metallic object (watch, ring etc.) which can cause short circuit. - Use insulated tools • Before wearing the protective gear, make sure that they are not torn or broken and free of moisture. • Personal Protection Equipment : Insulating Gloves, Safety Glasses Insulating Gloves Safety Glasses • Use Mega Ohm Tester when measuring insulation resistance of the high voltage system. Specification : High Impendance Digital Volt / Ohm Meter (DVOM) "Category 3" Leads and Meter rated to 1,000 voltage. Be sure to shut off the high voltage circuit shown in the procedures below before working on any high voltage system component. (Refer to "High Voltage Shutoff Procedure" for more detailed procedures) 1) Turn the ignition switch off and disconnect the auxiliary 12V battery negative (-) cable.

2) Remove the safety plug (Turning the ignition switch ON with the safety plug removed may damage the hybrid control system). 3) Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged. 4) Remove the rear seat and partition tray trim (Refer to “Seat” in BD group). 5) Remove the high voltage front cover (A). Measure the voltage between the inverter positive and negative power cable terminals. Below 30V : High voltage circuit properly shut More than 30V : High voltage circuit faulty • Attach the 'High Voltage Caution Car Topper' to the vehicle roof to inform other people of danger of high voltage.

Be sure to follow instructions below when repairing the high voltage cable. • Check the voltage of the high voltage connector, terminal or busbar before repairing. Below 30V : High voltage circuit properly shut More than 30V : High voltage circuit faulty • Be careful not to short circuit between positive (+) and negative (-) terminals.

• Insulate the high voltage connector or terminal with an insulation tape after disconnecting. • Tighten the high voltage terminal with the specified torque. • The high voltage battery must be always handled horizontally during repairing or storage. Otherwise, there may be decline in battery performance or its life may be shortened. • Exposing the high voltage battery to intense heat may cause deterioration. • Do not bake over 70°C (158°F) / 30 min or 80°C (176°F) / 20 min when painting. Precautions in case of fire on the high voltage battery system • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. • Quickly disconnect the service interlock connector plug in the early stage of fire. (Refer to Hybrid Control System - "High Voltage Shut-off Procedure") • Turn OFF the vehicle key as soon as possible and evacuate to the outside if the vehicle stops after a flooding/collision accident. • If a small 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 the safe place and keep people out of the vehicle. • Call fire station and report the vehicle is on fire. Follow the instruction from 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 to extinguish. It is difficult to extinguish the fire if there are not enough water or proper fire extinguisher. Approaching the vehicle may lead to life damage such as electrical shock. Precaution for vehicle fire If a small 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 the safe place and keep people out of the vehicle. • Call fire station and report the vehicle is on fire. Follow the instruction from 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 to extinguish. It is difficult to extinguish the fire if there are not enough water or proper fire extinguisher. Approaching the vehicle may lead to life damage such as electrical shock. Hybrid Vehicle Refrigerant Recovery / Charging Precautions • Since the electric compressor uses high-voltage, you should use PVE or POE oil which have high Volumetric Resistivity. • Do not use the same A/C recovery / charging station as conventional belt-driven compressors. If the PVE or POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.

SONATA Hybrid(YF HEV) > 2011 > G 2.4 HEV > General - High Voltage Shutoff Procedure Shut off the high voltage circuit before doing any work related with the high voltage system (Battery Pack Assembly, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC Power Cable, Electric Compressor, and so on). 1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable. 2. Remove the safety plug. (1) Open the safety plug service cover (A). (2) Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug. 3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged. 4. Make sure that the capacitor has been discharged. (1) Remove the rear seat and partition tray trim (Refer to “Seat” in BD group). (2) Remove the high voltage front cover (A).

High voltage front cover installation bolt : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) (3) Measure the voltage between the inverter positive and negative power cable terminals. Below 30V : High voltage circuit properly shut More than 30V : High voltage circuit faulty If the measured voltage is more than 30V, check the removal of the safety plug again. If it is above 30V even though the safety plug is properly removed, there must be any serious problem in high voltage circuit. In this case, do the DTC troubleshooting first (Refer to DTC Guide); don''t do any work related to the high voltage system.

SONATA Hybrid(YF HEV) > 2011 > G 2.4 HEV > General - Identification Number Locations Identification Number Description Vehicle Identification Number 1. World Manufacturer Identifier (WMI)

- KMH : Passenger vehicle or MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational Vehicle) 2. Vehicle line - E : SONATA 3. Model ＆ Series - A : Low grade (L) - B : Middle-Low grade (GL) - C : Middle grade (GLS, JSL, TAX) - D : Middle-High grade (HGS) - E : High grade (TOP) 4.Body/Cabin type, Gross Vehicle Weight Rating - 4 : Sedan - 4 door 5. Restraint system, Brake system Code Seat belt Front air bag Knee air bag Side air bag Curtain air bag Driver''s Passenger''s Driver''s Passenger''s 1st row 2nd row 3rd row 1st row 2nd row 3rd row A ○ ○ ○ × × ○ × × ○ ○ × B ○ ○ ○ × × × × × × × × C ○ ○ ○ × × ○ × × ○ ○ ○ D ○ ○ ○ × × ○ ○ × ○ ○ × E ○ ○ × × × × × × × × × F ○ ○ ○ × × ○ × × × × × J ○ ○ ○ ○ × ○ ○ × ○ ○ × L ○ ○ ○ ○ × ○ × × ○ ○ × N ○ × × × × × × × × × × 6. Engine type - 4 : Gasoline 2.4 DOHC/ [Li-PB] : 270(V), 5.3 (Ah)/ [3-phase AC] : 30 (kw) 7. Check digit or Driver’s side & Transmission - Check digit : 0 ~ 9, × 8. Production year - A : 2010, B : 2011, C : 2012, D : 2013 … 9. Plant of production - A : Asan (Korea) 10. Vehicle production sequence number - 000001 ~ 999999 Paint Code Code Color AA Black diamond WHC White crystal Y5 Sleek silver FHM Hyper metallic YDG Dark gray RER Remington red V5G Bronze gray Y2U Hybrid blue

PAB Blue passion Engine Number 1. Engine fuel - G : Gasoline 2. Engine range - 4 : 4 cycle 4 cylinder 3. Engine development order and capacity - K : Theta engine (Gasoline) 4. Engine Capacity - K : 2359cc (Theta-II HEV engine) 5. Production year - A : 2010, B : 2011, C : 2012... 6. Plant of production - A : Asan (Korea) - B : Beijing (China) - H : Hwasung (Korea) - K : Montgomery (U.S.A) - M : Chennai (India) - P : Poseung (Korea) - S : Sohari (Korea) - T : Izmit (Turkey) - U : Ulsan (Korea) - W : Shandong (China) - Z : Zilina (Slovakia) - 1 : Yancheng (China) 7. Engine production sequence number - 000001 ~ 999999 Transaxle Number 1. Model - HA: A6MF2H (Theta-II 2.4 HEV, 2WD, water cooling) 2. Production year - A : 2010, B : 2011, C : 2012... 3. Gear ratio - S : 3.320 4. Detailed classification - A : Theta-II 2.4 HEV 5. Spare 6. Transaxle production sequence number - 000001 ~ 999999

Warning / Caution Label Locations 1. Fan caution 2. Radiator cap caution 3. Auxiliary 12V battery caution 4. High voltage caution 5. High voltage battery caution Hybrid System Safety Precaution This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution. A caution label for high voltage is attached to the high voltage components. The color of the high voltage cables and connectors are orange. Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE). High Voltage Component: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable etc.

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2011 Hyundai SONATA Hybrid (YF HEV) G 2.4 HEV Service & Repair Manual

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