2017 Hyundai SONATA Plug-in Hybrid (LF PHEV) G 2.0 PHEV Service & Repair Manual

SONATA Plug-in Hybrid(LF PHEV) > 2017 > G 2.0 PHEV > - Safety Precaution Precautions to take before servicing high voltage system • Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly,this may lead to a serious accident from electric shock or leakage. • Be sure to shut off the high voltage by removing the safety plug before performing inspection or repairing the high voltage system. (Refer to "High Voltage Shut-off Procedures") • The responsible worker keeps the removed safety plug to prevent the plug from being connected by mistake. • Do not wear any metal objects (watch, ring, etc) while working on the high voltage system as it may cause and accident from electrical shock. • Before beginning work on the high voltage system, the worker should wear personal protective equipment to prevent safety accidents. (Refer to "Personal Protective Equipment") • Never allow workers who are not wear personal protective equipment to touch the high voltage system. High voltage components should be covered with an insulation sheet to prevent safety accidents. • Use insulated tools when working on the high voltage system. • 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 the high voltage wiring and connectors are orange. • A caution label for high voltage is attached to the high voltage components. • High voltage components : High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, On-Board Charger (OBC) Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor etc. • Place a high voltage caution sign on top of the vehicle when working on high voltage as shown in the picture below.

Personal Protective Equipment Name Illustration Description Insulation glove Used when inspecting or working on the high voltage components [Insulation performance : 1000V / 300A or above]

Safety glasses Used in the case below • During Removal & installation or inspection of the high voltage battery terminals or wiring, which spark might happen. • During working on the high voltage battery pack assembly. Precautions to take when handling power cable • Immediately insulate the high voltage terminal after removing the terminal (use insulation tape). • Tighten the high voltage terminal screw to spec torque. • Be careful that (+) and (-) terminals do not come in contact when connecting or disconnecting power cable and busbar. Precautions to take when handling high voltage battery • When transporting high voltage battery, be sure to keep it flat and level. Failure to do so may decrease the battery performance and/or its life-span. • High voltage battery's performance may decrease if it is exposed to high temperature for a long period. As a result, heat-treatment after painting must not exceed 70°C/30 minutes, or 80°C/20 minutes. 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. Precautions in case of high voltage battery gas or electrolyte leakage • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. • Gas is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location. • If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution. • If the leaked vapor or liquid gets in the eye, immediately clean the affected eye with water then get medical attention. • If the gas leakage is caused by high temperature, then do NOT use the battery until the high voltage battery fully cools down to room temperature. Precautions when handling the vehicle after an accident • Be sure to wear insulated gloves (or rubber gloves), protective goggles. • Do NOT touch bare cable under any condition. (Refer to "Precautions when handling power cable")

• If the vehicle is flooded, do not come close to the high voltage related parts. If the situation is unavoidable, move the vehicle to a safe place before taking action. • Gas from the high-voltage battery is hydrogen and alkaline vapor. If the leakage is indoor, ventilate the area immediately and evacuate to a safe location. • If the leaked liquid comes in contact with skin, immediately neutralize the affected area with boric acid solution, then clean with tap water or saline solution. • Refer to "High voltage cut-off procedure" if the high voltage needs to be cut off. 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. Preparations when servicing the accident vehicle • Be sure to wear insulated gloves (or rubber gloves), protective goggles. • Boric Acid Power or Solution • ABC Extinguisher • Towel for cleaning electrolyte • Vinyl tape (for insulating terminal) • Mega ohm tester (for checking high voltage) Precautions in case HEV is left unattended for a long period • Turn OFF the Start button. Keep the Smart Key at least 2 meters away from the vehicle to prevent unintended engine start. • We recommend that HEV is driven at least 1 time for over 30 minutes every 2 months to protect and manage the high voltage battery (inquire at relevant team in HMC). • When inspecting or exchanging the auxiliary battery, check high voltage battery SOC reset related problems. Hybrid Vehicle Refrigerant Recovery / Charging Precautions • Since the electric compressor uses high-voltage, you should use POE oil which have high Volumetric Resistivity. • Do not use the same A/C recovery / charging station as conventional belt-driven compressors. • If the 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 Plug-in Hybrid(LF PHEV) > 2017 > G 2.0 PHEV > 12345678910 - High Voltage Shut-off Procedures • Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. • Be sure to read and follow the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. High voltage components : 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. 1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) terminal. 2. Remove the luggage cover board. (Refer to Body - "Trunk Trim") 3. Remove the side luggage form [RH]. (Refer to Body - "Trunk Trim") 4. Remove the installation bolts (A), and then remove the safety plug cover (B). 5. Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (B) to the direction of arrow.

6. Wait for more than 5 minutes so that the capacitor in the high voltage system can be fully discharged. 7. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely. (1) Remove air cleaner assembly and air duct. (Refer to Engine Mechanical System - "Air Cleaner") (2) Disconnect the inverter power cable (A). Disconnect the inverter power cable as the procedures below. (3) Measure the voltage between the inverter (+) terminal and the inverter (-) terminal. Less than 30V : High voltage circuit properly shut More than 30V : Fault on high voltage circuit

If measured more than 30V, check if the safety plug is removed completely.If measured more than 30V despite the safety plug is removed, there can be serious problems on the high voltage circuit. In this case, check DTC and never touch the high voltage system circuits.

SONATA Plug-in Hybrid(LF PHEV) > 2017 > G 2.0 PHEV > - High voltage battery system inspection guide Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. 1. Carry out a visual inspection to determine whether the vehicle requires general repair or accident repair. 2. For the general repair, perform the repair based on the repair process for that DTC code. 3. For the car accident repair, determine the accident type before repair. 1) Electrical Accidents – Over-charge/discharge : Displays a battery over voltage (P1B71) code /low voltage (P1B70) code (Refer to the DTC diagnosis guide). – Short : Displays a high voltage short (P1B77, P1B25) codes (Refer to the DTC diagnosis guide). 2) Fire Classification Inspection process Inspection results Measures Fire outside of the high voltage battery mount ※Example) Engine fire 1. Perform visual inspections (deformation, corrosion, wire coating, odor, connector). 2. Check for main fuse open circuit after shutting off the high voltage. 3. Check the high voltage main relay for signs of welding. 4. Measure the high voltage battery/chassis insulation resistance. 5. Check other parts for failure. 6. Check the DTC code in the BMS ECU. High voltage battery insulation damaged Remove the high voltage battery and repair the insulation process/coating. High voltage battery not damaged DTC code If a DTC code occurs, comply with DTC diagnosis guide and repair process. No DTC code and battery appears normal Do not replace the high voltage battery. (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process) Fire in the high voltage battery mount ※Example) Trunk fire 1. Perform visual inspections (deformation, corrosion, wire coating, odor, connector). 2. Check for visible damage of the high voltage battery. 3. Check the high voltage main relay for signs of welding after shutting off the high voltage if no visible damage is found in the high voltage battery. 4. Measure the high voltage battery/chassis insulation resistance. 5. Check other parts for failure. 6. Check the DTC code in the BMS ECU. High voltage battery appears damaged. (heat, soot, etc.) Remove the service disconnect plug and perform the salt water battery disposal process. High voltage battery insulation damaged Remove the high voltage battery and repair the coating/insulation. High voltage battery not damaged DTC code If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide. No DTC code and battery appears normal Do not replace the high voltage battery. (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process) 3) Collision Classification Inspection process Inspection results Measures

Collision damage to areas other than the high voltage battery mount ※Example) Front/side collision 1. Perform visual inspections (deformation, corrosion, wire coating, odor, connector). 2. Check for main fuse open circuit after shutting off the high voltage. 3. Check the high voltage main relay for signs of melting. 4. Measure the high voltage battery/chassis insulation resistance. 5. Check other components. 6. Check the DTC code in the BMS ECU. High voltage battery insulation damaged Remove the high voltage battery and repair the coating/insulation. High voltage battery not damaged DTC code If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide. No DTC code and battery appears normal Do not replace the high voltage battery. (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process) Collisions involving the high voltage battery mount ※Example) Rear-end collision 1. Perform visual inspections (deformation, corrosion, wire coating, odor, connector). 2. Check for main fuse open circuit after shutting off the high voltage. 3. Check the high voltage main relay for signs of melting. 4. Measure the high voltage battery/chassis insulation resistance. 5. Check other components. 6. Check the DTC code in the BMS ECU. High voltage battery insulation damaged ⇑ Follow the measures outlined above. ※ If the high voltage battery mount is inaccessible due to trunk or door damage, bend or cut the exterior panels without damaging the high voltage system and carry out the inspection and repair process. High voltage battery not damaged DTC code No DTC code and battery appears normal 4) Submersion Classification Inspection process Inspection results Measures High voltage battery not submerged 1. Perform a visual inspection (deformation, corrosion, wire coating, odor, connector). 2. Check for main fuse open circuit after shutting off the high voltage. 3. Check the high voltage main relay for signs of melting. 4. Measure the high voltage battery/chassis insulation resistance. 5. Check other components. 6. Check the DTC code in the BMS ECU. High voltage battery insulation damaged Remove the high voltage battery and repair the coating/insulation. High voltage battery not damaged DTC code If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide. No DTC code and battery appears normal Do not replace the high voltage battery (if the battery is damaged and must be disposed of, perform the high voltage battery disposal process). High voltage battery submerged [Regardless of water conditions] 1. Check for main fuse open circuit after shutting off the high voltage. 2. Check the high voltage main relay for signs of melting. 3. Measure the high voltage battery/chassis insulation resistance. Carry out these measures regardless of the inspection results Remove the high voltage battery and repair the coating/insulation.

4. Check the DTC code in the BMS ECU. Checking for Welding in the High Voltage Main Relay In order to safely remove the battery pack assembly, you must first inspect the high voltage main relay for signs of weld damage. You can use Gloval Diagnostic System (GDS) service data to detect weld damage in the high voltage main relay. [Using GDS service data to check for main relay weld damage] 1. Connect the GDS to the self-diagnosis connector (DLC). 2. Turn on the ignition. 3. Check the BMS weld damage state in the GDS service data. [Using a Multimeter to measure weld damage] Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. 1. Shut off the high voltage. (Refer to "High Voltage Shut-off Procedures") 2. Remove the rear seat assembly. (Refer to Body - "Rear Seat Assembly") 3. Remove the luggage partition center trim. (Refer to Body - "Trunk Trim") 4. Unfasten bolt (A) and remove the front cover from the high voltage battery (B).

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2017 Hyundai SONATA Plug-in Hybrid (LF PHEV) G 2.0 PHEV Service & Repair Manual

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