Hyundai Ioniq: Hybrid Motor Assembly / Hybrid Starter Generator(HSG). Repair procedures
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| When working on the high voltage system, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings". If you do not comply with them, a serious accident such as electric shock or leakage may occur. |
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| When working on the high voltage system, make sure that you cut off the high voltage first according to the "High Voltage Cut-off Procedure". If you do not comply with them, a serious accident such as electric shock or leakage may occur. |
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| Use a fender cover to prevent damage of the vehicle painting. |
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| Make sure that connectors and wiring are not damaged when separating them. |
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| Mark the wiring connectors and hoses to prevent wrong connection. |
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1. | Cut off the high voltage. (Refer to Generals - "High Voltage Cut-off Procedure".) |
2. | Open the drain plug to discharge inverter coolant. Leave the reservoir cap open for smooth discharge. (refer to Hybrid Motor Cooling System - "Coolant".) |
3. | Remove the drive belt. (Refer to Engine Mechanical System - "Drive Belt".) |
4. | Remove the engine mounting support bracket. (Refer to Engine Mechanical System - "Engine Mounting".) |
5. | Remove the mechanical drive belt tensioner. (Refer to Engine Mechanical System - "Drive Belt Tensioner".) |
6. | Remove the timing chain cover idler. (Refer to Engine Mechanical System - "Idler".) |
7. | Disconnect the HSG sensor connector (A). |
8. | Remove the cooler hose (A) from the HSG. |
9. | Remove the intake manifold. (Refer to Engine Mechanical System - "Intake Manifold".) |
10. | Disconnect the HSG high-voltage cable connector (A). |
11. | Remove the HSG support bracket mountine bolts (A). Tightening torque : 44.1 - 53.9 N.m (4.5 - 5.5 kgf.m, 32.5 - 39.8 lb-ft) |
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12. | Remove the HSG (A). Tightening torque : 44.1 - 49.0 N.m (4.5 - 5.0 kgf.m, 32.5 - 36.1 Ib-ft) |
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| Be careful not to cause any damage on the hose when tightening the clamp. |
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| Mount the clamp tightening part in the designated direction so that interference does not occur with the adjacent parts. |
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1. | To install, reverse the removal procedure. |
2. | Perform resolver sensor compensation. Perform compensation according to the GDS motor / HSG resolver compensation procedure shown below. |
3. | Fill the coolant in the hybrid cooling system and use the GDS to perform air bleeding. (Refer to Hybrid Motor Cooling System - "Coolant".) |
4. | Check for the leakage in the hose connections while the engine is running. |
1. | Use the mΩ tester to check the line resistance.
Category
| Inspection Based on
| Inspection Area
| Inspection method
| Remarks
| Resistance (Line - Line)
| U - V
| 195 mΩ± 5%
| Measuring equipment: Milliohm meter Measuring point: U - V - W Line resistance per part Applied current : 10 A
| Change depending on temperature: + 0.4%/°C
| V - W
| W - U
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2. | Check the temperature sensor resistance.
Category
| Inspection Based on
| Inspection Area
| Inspection method
| Remarks
| Resistance (Temperature sensor)
| Pin 4 - 9
| 10.92 - 13.44 kΩ
| Measuring equipment: Multimeter
| Based on ambient temperature (20°C)
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3. | Check the resolver sensor resistance.
Category
| Inspection area
| Inspection criteria
| Remarks
| Resistance (Resolver sensor)
| Pin 1 - 6
| 15.8 ± 2Ω
| Based on ambient temperature (23°C)
| Pin 2 - 7
| 28.2 ± 2Ω
| Pin 3 - 8
| 28.2 ± 2Ω
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4. | Perform the insulation test.
Category
| Inspection Based on
| Inspection Area
| Inspection method
| Remarks
| Insulation (Housing, cover)
| W - U - V
| 10 MΩ↑
| Measuring equipment: Voltage tester Measuring method : After 3-phase short-circuit Measurement between the phase and housing
| DC 540 Vdc, 1 min
| 5 mA↓
| AC 1600 Vac, 1 min
| Position (resolver) sensor
| 10 MΩ↑
| DC 500 Vdc, 1 min
| Temperature sensor
| 10 MΩ↑
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Specifications
Classification
Unit
Specifications
VoltageVdc204DrivingTorqueNm / rpm / sec35...
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