Hyundai Ioniq: Hybrid Control System / Troubleshooting
Basic Inspection Procedure
| Measuring Condition of Electronic Parts' Resistance |
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient temperature (20°C, 68°F), unless stated otherwise.
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| The measured resistance in except for ambient temperature (20°C, 68°F) is reference value. |
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| Intermittent Problem Inspection Procedure |
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which occurred when the vehicle was having the issue.
| 1. | Clear Diagnostic Trouble Code (DTC). |
| 2. | Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and then verify that the connectors are always securely fastened. 
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| 3. | Slightly shake the connector and wiring harness vertically and horizontally. |
| 4. | Repair or replace the component that has a problem. |
| 5. | Verify that the problem has disappeared with the road test. |
● Simulating Vibration
| a. | Sensors and Actuators : Slightly vibrate sensors, actuators or relays with finger. | •
| Strong vibration may break sensors, actuators or relays |
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| b. | Connectors and Harness : Lightly shake the connector and wiring harness vertically and then horizontally. |
● Simulating Heat
| a. | Heat components suspected of causing the malfunction with a hair dryer or other heat source. | •
| DO NOT heat components to the point where they may be damaged. |
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| DO NOT heat the ECM directly. |
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● Simulating Water Sprinkling
| a. | Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition. | •
| DO NOT sprinkle water directly into the engine compartment or electronic components. |
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● Simulating Electrical Load
| a. | Turn on all electrical systems to simulate excessive electrical loads. (Radios, fans, lights, rear window defogger, etc.) |
Connector Inspection Procedure
| 1. | Handling of Connector | a. | Never pull on the wiring harness when disconnecting connectors. 
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| b. | When removing the connector with a lock, press or pull locking lever. 
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| c. | Listen for a click when locking connectors. This sound indicates that they are securely locked. 
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| d. | When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side. 
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| e. | Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side. 
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| Use a fine wire to prevent damage to the terminal. |
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| Do not damage the terminal when inserting the tester lead. |
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| 2. | Checking Point for Connector | a. | While the connector is connected : Hold the connector, check connecting condition and locking efficiency. |
| b. | When the connector is disconnected : Check missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness. Visually check for rust, contamination, deformation and bend. |
| c. | Check terminal tightening condition : Insert a spare male terminal into a female terminal, and then check terminal tightening conditions. |
| d. | Pull lightly on individual wires to ensure that each wire is secured in the terminal. 
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| 3. | Repair Method of Connector Terminal | a. | Clean the contact points using air gun and/or shop rag. | •
| Never use sand paper when polishing the contact points, otherwise the contact point may be damaged. |
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| b. | In case of abnormal contact pressure, replace the female terminal. |
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Wire Harness Inspection Procedure
| 1. | Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly. |
| 2. | Check whether the wire harness is twisted, pulled or loosened. |
| 3. | Check whether the temperature of the wire harness is abnormally high. |
| 4. | Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part. |
| 5. | Check the connection between the wire harness and any installed part. |
| 6. | If the covering of wire harness is damaged; secure, repair or replace the harness. |
Electrical Circuit Inspection Procedure
| 1. | Procedures for Open Circuit If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method) as shown below. 
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| 2. | Continuity Check Method | •
| When measuring for resistance, lightly shake the wire harness above and below or from side to side. |
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Specification (Resistance) 1Ω or less → Normal Circuit 1MΩ or Higher → Open Circuit |
| a. | Disconnect connectors (A), (C) and measure resistance between connector (A) and (C) as shown in [FIG. 2]. In [FIG.2.] the measured resistance of line 1 and 2 is higher than 1kΩ and below 1Ω respectively. Specifically the open circuit is line 1 (Line 2 is normal). To find exact break point, check sub line of line 1 as described in next step. 
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| b. | Disconnect connector (B), and measure for resistance between connector (C) and (B1) and between (B2) and (A) as shown in [FIG. 3]. In this case the measured resistance between connector (C) and (B1) is higher than 1MΩ and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). 
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| 3. | Voltage Check Method | a. | With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and (C) as shown in [FIG. 4]. The measured voltage of each connector is 5V, 5V and 0V respectively. So the open circuit is between connector (C) and (B). 
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| 1. | Test Method for Short to Ground Circuit | •
| Continuity Check with Chassis Ground |
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity Check Method with Chassis Ground) as shown below. 
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| 2. | Continuity Check Method (with Chassis Ground) | •
| Lightly shake the wire harness above and below, or from side to side when measuring the resistance. |
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Specification (Resistance) 1Ω or less → Short to Ground Circuit 1MΩ or Higher → Normal Circuit |
| a. | Disconnect connectors (A), (C) and measure for resistance between connector (A) and Chassis Ground as shown in [FIG. 6]. The measured resistance of line 1 and 2 in this example is below 1Ω and higher than 1MΩ respectively. Specifically the short to ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as described in the following step. 
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| b. | Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground as shown in [FIG. 7]. The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1). 
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Other information:
C..
Removal1. Disconnect the vapor hose (A).2. Remove the PCV valve (B).Inspection1.Insert a thin stick (A) into the PCV valve (B) from the threaded side to check that the plunger movement.
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If the plunger does not move (PCV valve is clogged), clean or replace the valve...
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