23-01-060H

GROUP
Technical Service Bulletin
NUMBER
CAMPAIGN
23-01-060H
DATE
MODEL(S)
JULY 2023
IONIQ 5 (NE1)
IONIQ 6 (CE1)
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT
AND ICCU SOFTWARE UPDATE (SERVICE CAMPAIGN 997)
SUBJECT:
 IMPORTANT
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail
delivery and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the “Vehicle Information” screen via WEBDCS to identify open campaigns.
Description: Certain 22-23MY Ioniq 5 (NE1) & 23MY Ioniq 6 (CE1) vehicles may have a condition
where low 12V auxiliary battery charging occurs due to an ICCU (Intelligent Charging Control Unit)
fault and may set the following DTC P1A9096 – “DC/DC Converter Input Voltage Sensor Fault”.
When a fault occurs, the vehicle may enter a reduced power mode while various warning lights, an
audible chime will sound, and large messaging in the vehicle’s instrument cluster will appear and
instruct the driver to stop the vehicle.
The Service Procedure flow to be followed is outlined by the flowchart on Page-3. The ICCU system
is to be checked by GDS for DTC P1A9096 and depending on the result, will involve either an ICCU
software update, or ICCU and potential fuse replacement. Only replace the fuse after it is inspected to
confirm to be blown/open.
Applicable Vehicles (Certain):
• 2022-23MY IONIQ 5 (NE1) produced from 10/04/2021 - 06/22/2023
• 2023MY IONIQ 6 (CE1) produced from 12/14/2022 - 06/20/2023.
NOTICE
This service campaign can only be performed at certified IONIQ Hyundai dealers.
GDS Information:
System
Event #
Description
NE1
ICCU
OVER-CURRENT
DIAGNOSTIC ENHANCEMENT UPGRADE
ICCU
1001*
ICCU
1005* CE1 ICCU OVER-CURRENT DIAGNOSTIC ENHANCEMENT UPGRADE
* or select the latest available Event # that displays in GDS.
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
Parts Information:
Part Name
Integrated Charge
Control Unit (ICCU)
Fuse**
Model
Part Number
Ioniq 5
(NE1)
36400-1XAA0QQH
Ioniq 6
(CE1)
36400-1XEA0QQH
Both
Remark
375F2-GI040QQH
As needed only if DTC P1A9096 stored:
Order this fuse with an ICCU.
**However, per section-E only install the
fuse after ICCU is replaced, should
inspection of the fuse confirm it is
blown/open.
**CAUTION: Do not install fuse before ICCU replace. DTC P1B77 Battery PRA damage will occur.
Coolant (LLC-10)
Both
00232-19098
Pink coolant. Up to 1 Gallon.
Warranty Information:
MODEL
Ioniq 5
(NE1) &
Ioniq 6
(CE1)
OP CODE
OP NAME
CAUSAL PART
30D073R0
DTC CHECK AND ICCU
SOFTWARE UPDATE
30D073R1
DTC CHECK, ICCU REPLACE
AND FUSE INSPECTION
36400-1XAA0QQH
(Ioniq 5)
36400-1XEA0QQH
(Ioniq 6)
OP
TIME
NATURE
CAUSE
I3A
ZZ3
0.4 M/H
2.1 M/H
NOTE 1: Software update or ICCU/fuse replacement due to DTC P1A9096 is to be submitted on the
Claim Entry Screen as "Campaign" type. If other DTC other than P1A9096 appears during inspection,
perform the appropriate diagnosis per shop manual and submit as normal warranty.
NOTE 2: Op code 30D073R1 will reimburse for 1 Gallon of Coolant and for the fuse regardless if fuse
is used or not.
NOTE 3: If a part is found in need of replacement while performing this campaign and the affected
part is still under warranty, submit a separate claim using the same repair order. If the affected part is
out of warranty, submit a Prior Approval request for goodwill consideration prior to performing the
work.
NOTE 4: This TSB includes Repair validation photos. Op times including VIN, Mileage, and Repair
validation photos as outlined in the Digital Documentation Policy.
NOTE 5: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
TSB #: 23-01-060H
Page 2 of 16
SUBJECT:
SUBJECT:
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
Table Of Contents:
Section
Pages
A
4
B
4-6
C
7-9
D
10-13
E
14-16
Description
DTC CHECK
ICCU SOFTWARE UPDATE
ICCU REPLACEMENT FOR THE IONIQ 5 (NE1)
ICCU REPLACEMENT FOR THE IONIQ 6 (CE1)
EV BATTERY ICCU FUSE INSPECTION
Summary of Service Procedure Flow:
NOTE: See Campaign Bulletin Procedure Video at: https://vimeo.com/845260120/1351eab6b2
TSB #: 23-01-060H
Page 3 of 16
SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
A. DTC CHECK
A1.
Perform All Fault Search by GDS.
A2.
Check the ICCU system for DTC P1A9096 either found as an active or history DTC?
➢ No – (DTC P1A9096 is not found stored):
• Perform ICCU Software Update – see section B. (Campaign Claim 0.4 M/H)
• NOTE: If any other DTC or symptom is found stored, diagnose and repair per shop
manual before performing the ICCU Update. (Warranty Claim)
➢ Yes – (DTC P1A9096 is found stored):
• Replace ICCU:
o Ioniq 5 (NE1) – see section C
o Ioniq 6 (CE1) – see section D
• Inspection to determine whether or not to replace the Fuse – see section E.
(replace only if the fuse is confirmed to be blown/open)
(Campaign Claim 2.1 M/H)
B. ICCU SOFTWARE UPDATE
B1.
! WARNING
GDS Vehicle Battery Voltage:
• This ICCU Update is long, so the 12V battery must be at good charge level (>60%
SOC). Attach a Battery Charger to maintain the 12V battery if the vehicle had the
DTC P1A9096 incident, as it would be more likely that the 12V Battery will be low.
• If the voltage is below 12 volts as per the GDS warning, then select Back and run
the vehicle at least 30 minutes to reach an adequate battery state of charge to
prevent an ECU Update failure. Cycle the ignition OFF/ON before retrying the ECU
update again.
i Information
GDS ECU Updates must be performed in Auto Mode.
• If ECU Update starts but then fails in Auto Mode, perform update in Manual Mode
to recover.
• Turn off ignition for 30 seconds and try Manual Mode recovery.
• If unsuccessful, re-attempt Manual Mode after disconnecting the cables from the
12V battery terminals and performing cap discharge (connecting bar or heavy wire
between “+” to “-“ cables).
TSB #: 23-01-060H
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SUBJECT:
SUBJECT:
B2.
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
Perform the ICCU Update in Auto Mode.
Use the Auto Mode ID Check to verify the VCU
ROM ID before updating the software.
B3.
After the ECU Upgrade process shows 100% complete, cycle the ignition key to OFF for at least
10 seconds to reset the control unit.
B4.
Take a screenshot of the ECU Update complete screen and upload to STUI.
STUI
Take a screenshot of the ECU Update
Complete screen using your particular
tablet’s screenshot save method and
upload to STUI.
TSB #: 23-01-060H
EXAMPLE
Page 5 of 16
SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
ROM ID Information table:
VEHICLE
SYSTEM
ROM ID
ICCU P/No.
OLD
NEW
ENE1E3-IDS11R000
ECE1E3-IDS03R000
Ioniq 5
(NE1 EV)
ICCU
36401-1XAA0
ENE1E1-IDS02R000
ENE1E1-IDS51R000
ENE1E1-IDS03R000
ENE1E1-IDS05R000
ENE1E1-IDS07R000
ENE1E1-IDS08R000
ENE1E1-IDS09R000
ENE1E3-IDS10R000
Ioniq 6
(CE1 EV)
ICCU
36401-1XEA0
ECE1E3-IDS02R000
Manual Mode Password Information:
ICCU Event 1001:
MENU
NE1 EV ICCU 36401-1XAA0
PASSWORD
1384
MENU
CE1 ICCU 36401-1XEA0
PASSWORD
1331
ICCU Event 1005:
TSB #: 23-01-060H
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SUBJECT:
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
SUBJECT:
C. ICCU REPLACEMENT FOR THE IONIQ 5 (NE1)
C1.
Shut off the high voltage circuit and wait 5
minutes for capacitors to discharge.
i
Information
Refer to the shop manual:
Battery Control System > High Voltage
Shut-off Procedures
C2.
Drain the motor coolant.
i
Information
Refer to the shop manual:
Cooling System > Motor Cooling System
> Coolant
C3.
Remove the rear seat assembly.
i
Information
Refer to the shop manual:
Body (Interior and Exterior) > Rear Seat
> Rear Seat Assembly
C4.
Remove the luggage side trim.
i
Information
Refer to the shop manual:
Body (Interior and Exterior) > Trunk Trim
> Luggage Side Trim
C5.
Remove the ground (A) after removing the
mounting bolt.
Tightening Torque:
lb-ft
7
lb-in
84
N.m
9
A
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SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
C6.
Disconnect the ICCU AC connector (B).
B
C7.
Disconnect the ICCU DC connector (C) and
ICCU signal connector (D).
C
D
C8.
After loosening the mounting bolts, remove the
LDC plus (E).
Tightening Torque:
lb-ft
7
lb-in
84
N.m
9
E
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SUBJECT:
SUBJECT:
C9.
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
Disconnect the coolant tube quick connectors
(F).
F
C10. After removing the mounting bolts, remove the
ICCU (G).
Torque Tightening:
lb-ft
19
N.m
25
C10. Install the replacement ICCU and take STUI
photo for upload once installed.
Install in the reverse order of the removal.
Refill the motor cooling system with coolant
and then fully bleed out air using the GDS
diagnostic tool.
STUI
EXAMPLE
Using STUI, take a photo of the new
ICCU with the last 6 digits of the VIN
and the date of repair on a piece of
paper. Upload the photo to STUI.
TSB #: 23-01-060H
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SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
D. ICCU REPLACEMENT FOR THE IONIQ 6 (CE1)
D1.
Shut off the high voltage circuit.
i
Information
Refer to the shop manual:
Battery Control System > High Voltage
Shut-off Procedures
Drain the motor coolant.
i
Information
Refer to the shop manual:
Cooling System > Motor Cooling System
> Coolant
Remove the rear seat cushion cover assembly.
i
Information
Refer to the shop manual:
Body (Interior / Exterior / Electrical) >
Rear Seat > Rear Seat Cushion Cover
Assembly
Remove the rear wheel house trim.
i
Information
Refer to the shop manual:
A
Body (Interior / Exterior / Electrical) >
Interior Trim > Rear Wheel House Trim
Disconnect the V2L signal connector (A).and
V2L extension connector (B).
B
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SUBJECT:
D2.
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
After removing the bolts and nuts, remove the
upper frame (C).
Torque Tightening:
D3.
lb-ft
19
N.m
25
C
Disconnect the ICCU AC connector (D).
D
D4.
After removing the bolt, Remove the LDC
ground (E).
Torque Tightening:
lb-ft
10
N.m
13
E
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SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
D5.
Disconnect the ICCU DC connector (F) and
ICCU signal connector (G).
G
F
D6.
After removing the bolt, remove the LDC (+)
(H).
Tightening Torque:
D7.
lb-ft
7
lb-in
84
N.m
9
H
Disconnect the coolant quick connector (I).
I
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DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
SUBJECT:
D8.
After removing the bolt, remove the ICCU (J).
J
Torque Tightening:
D9.
lb-ft
19
N.m
25
Install the replacement ICCU and take STUI
photo for upload once installed.
Install in the reverse order of the removal.
Refill the motor cooling system with coolant
and then fully bleed out air using the GDS
diagnostic tool.
STUI
EXAMPLE
Using STUI, take a photo of the new
ICCU with the last 6 digits of the VIN
and the date of repair on a piece of
paper. Upload the photo to STUI.
TSB #: 23-01-060H
Page 13 of 16
SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
E. EV BATTERY ICCU FUSE INSPECTION (Only applies after ICCU was replaced)
CAUTION
ONLY PERFORM THIS SECTION AFTER REPLACING THE ICCU.
Do not install fuse before the ICCU. DTC P1B77 EV Battery PRA damage will occur.
E1.
Shut off the high voltage circuit and wait 5
minutes for capacitors to discharge.
i
Information
Refer to the shop manual:
Battery Control System > High Voltage
Shut-off Procedures
E2.
Remove the rear under cover.
i
Information
Refer to the shop manual:
Motor and Reduction Gear System >
Rear Motor and Reduction Gear System
> Rear Under Cover
E3.
E4.
Disconnect the ICCU high voltage connector
(A).
A
Remove the ICCU high voltage connector
assembly cover (B).
Tightening Torque:
lb-ft
8
lb-in
96
N.m
10
B
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SUBJECT:
E5.
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
Remove the ICCU fuse cover (C).
C
E6.
Using a commonly available multimeter. Set at
the ohmmeter measuring mode and inspect
the fuse condition by checking the fuse’s
resistance value:
➢ Fuse is Good: Less than 1.0 ohm.
DO NOT REPLACE THE FUSE.
Do not follow the remaining steps to
replace the fuse.
➢ Fuse is Bad (Blown/Open):
Resistance greater than 1.0 ohm or OL.
CAUTION
ONLY REPLACE THE FUSE IF
FOUND TO BE BAD
(BLOWN/OPEN).
It can be difficult or with
complication removing the fuse,
which may include the nuts holding
the fuse holder falling back into the
battery.
TSB #: 23-01-060H
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SUBJECT:
SUBJECT DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE - (SERVICE CAMPAIGN 997)
E7.
Remove the ICCU fuse (D).
CAUTION
Avoid using power driver to remove and
install the bolts. Use a hand tool only.
There can be difficulty removing the
fuse, which may include the nuts of the
at the back of the fuse holder falling
back into the battery.
D
See the below special instruction
should this occur.
E8.
Install the supplied new ICCU fuse.
Install back in the reverse order of removal.
SPECIAL INSTRUCTION: Only applies when ICCU Fuse rear nut(s) falls back into the battery.
1. Remove:
o 6 qty. 10mm bolts (Green marked),
o 4 qty. bolts by Allen wrench (Red marked).
2. Push in bottom area. Pull out top area.
3. Reach in and grab the nut behind the plate on the
bottom surface.
4. Hold the nut at the back side.
5. Install the fuse bolt at the place that the nut had
dropped.
6. Install all the other bolts in reverse order of
removal.
7. Install the rest of the fuse bolts.
NOTE: Contact Techline if the above procedure did
not resolve a dropped nut problem.
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SUBJECT: