23-01-069G

CAMPAIGN
23-01-069G
AUGUST 2023
G80 Electrified
(RG3 EV)
GV60 (JW1 EV)
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT
AND ICCU SOFTWARE UPDATE (SERVICE CAMPAIGN 907G)
 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 2023MY G80 Electrified (RG3 EV) and 2023-24MY GV60 (JW1 EV), vehicles
may have a condition where low 12V auxiliary battery charging occurs due to an ICCU (Integrated
Charge 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 fuse replacement.
Applicable Vehicles (Certain):
• 2023MY G80 Electrified (RG3 EV)
• 2023-24MY GV60 (JW1 EV)
NOTICE
This service campaign can only be performed by EV certified Genesis retailers.
GDS Information:
ICCU
1002
RG3 EV ICCU OVER-CURRENT DIAGNOSTIC ENHANCEMENT UPGRADE
1003
JW ICCU OVER-CURRENT DIAGNOSTIC ENHANCEMENT UPGRADE
(*or use a later available event as listed in the GDS ICCU Update screen if one is available.)
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
Parts Information:
Integrated Charge
Control Unit
(ICCU)*
ICCU Fuse*
GV60 (JW1 EV)
36400-1XCA0QQH
G80 Electrified
(RG3 EV)
36401-1XBA0QQH
GV60 (JW1 EV)
375F2-GI040QQH
Order this fuse with an ICCU.
G80 Electrified
(RG3 EV)
18790-00728QQH
All
00232-19098
Coolant (LLC-10)
Pink coolant. Up to 1 Gallon each.
*As needed, only if DTC P1A9096 stored.
NOTICE
Do not install fuse alone without ICCU replacement. If Ready On occurs after replacing only
the fuse without replacing the ICCU, there is a possibility of DTC P1B77 Battery PRA damage.
Warranty Information:
ALL
30D074R0
GV60
(JW1 EV)
30D074R1
G80
Electrified
(RG3 EV)
30D074R2
DTC Check
and ICCU
Software
Update
0.4 M/H
DTC Check, 2.1 M/H
and ICCU and
Fuse
Replacement 3.3 M/H
36400-1XCA0QQH
(GV60)
36401-1XBA0QQH
(G80 Electrified)
36400-1XCA0QQH
I3A
ZZ3
36401-1XBA0QQH
NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: 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 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and repair
validation photos, as outlined in the Digital Documentation Policy.
NOTE 4: 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 #: 23-01-069G
Page 2 of 17
SUBJECT:
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
Table of Contents:
A
4
DTC Check
B
4-6
ICCU Software Update
C
7 - 15
ICCU Replacement for GV60 (JW1 EV)
D
16 - 18
ICCU Replacement for G80 Electrified (RG3 EV)
Summary of Service Procedure Flow:
TSB #: 23-01-069G
Page 3 of 17
SUBJECT:
A1.
Perform All Fault Search by GDS.
A2.
Check the ICCU system for DTC P1A9096. Is it 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 GV60 (JW1 EV) – see section C
o G80 Electrified (RG3 EV) – see section D
• Replace the Fuse – see section C8.
(WARNING: Do NOT only replace fuse only at first without replacing ICCU, it will
cause PRA damage)
(Campaign Claim 2.1 for JW1 or 3.3 M/H for RG3)
NOTICE
You must initially perform the GDS ECU Update in Auto Mode.
• If the ECU Update starts but then fails in Auto Mode, perform the update in Manual Mode
to recover.
NOTICE
GDS Vehicle Battery Low Voltage Warning:
The ICCU Update is a long ECU Update. If voltage is below 12 volts as per the below GDS
warning, then select Back and run the vehicle for at least 30 minutes to ensure an adequate
battery state of charge for reliable update results. Turn ignition back on, and then retry the ECU
update again.
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SUBJECT:
B1.
Perform the ECU Update in Auto Mode.
Use the Auto Mode ID Check to verify the
ECU ROM ID before updating the software.
i
Information
Refer to TSB 15-GI-001 for additional
tablet-based Mobile GDS ECU update
information.
B2.
STUI
Take a screenshot of the ECU Update
Complete screen using your particular
tablet’s screenshot save method and
upload to STUI.
B3.
EXAMPLE
After the ECU Upgrade process shows 100%
complete, cycle the ignition key to OFF for at
least 10 seconds to reset the control unit.
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SUBJECT:
B4.
Perform an All Systems Fault Code search
and erase the history of the DTC that had
incidentally occurred from the ECU update.
B5.
Start the vehicle in Ready mode to confirm
proper operation of the vehicle.
ROM ID Information Table: Event #1002
ERG3E1-IDS01R000
ERG3E1-IDS02R000
RG3 EV
ICCU
36401-1XBA0
ERG3E1-IDS51R000
ERG3E1-IDS04R000
ERG3E3-IDS07R000
ERG3E1-IDS05R000
ERG3E3-IDS06R000
ROM ID Information Table: Event #1003.
EJW1E1-IDS02R000
EJW1E1-IDS03R000
JW1 EV
ICCU
36401-1XCA0
EJW1E1-IDS04R000
EJW1E3-IDS07R000
EJW1E1-IDS05R000
EJW1E3-IDS06R000
Manual Mode Passwords:
1002
RG3 EV ICCU 36401-1XBA0
1381
1003
JW ICCU 36401-1XCA0
1371
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SUBJECT:
C1.
Disconnect the auxiliary 12V battery negative
(–) terminal (A).
A
C2.
Disconnect the high voltage cut-off switch (B)
in the direction of the arrow.
! CAUTION
B
Wait for more than 5 minutes so that the
capacitor in the high voltage system will
be fully discharged.
C3.
Open the coolant reservoir tank cap (C) to
release pressure.
C
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SUBJECT:
C4.
Raise the vehicle on a lift.
Loosen the rear undercover bolts and remove
the cover (D).
Tightening Torque:
C5.
lb-ft
6.5
lb-in
78
N.m
8.8
D
Disconnect the ICCU high voltage connector
(E).
E
C6.
Loosen the 4 bolts and remove the ICCU high
voltage connector assembly cover (F).
Tightening Torque:
lb-ft
7.3
lb-in
87
N.m
9.8
F
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SUBJECT:
C7.
Using a T3 Hex bolt wrench, unscrew the
three (3) hex bolts and remove the ICCU fuse
cover (G).
G
Tightening Torque:
C8.
lb-ft
2.2
lb-in
26
N.m
2.9
Using a T5 Hex bolt wrench, loosen the hex
bolts fixed by fuses (2 each) and remove the
ICCU fuse (H). Replace the fuse with the
newly provided one.
Reinstall all removed parts in reverse order of
disassembly.
Tightening Torque:
C9.
lb-ft
3.7
lb-in
44
N.m
4.9
H
Disconnect the rear coolant hose (I) and front
coolant hose (J).
I
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SUBJECT:
C10. Insert an air gun into the rear coolant hose (I)
to blow out internal coolant of the ICCU as
shown in the photo.
Rear Side of Battery Pack
Then, the ICCU coolant will be drained
through the front coolant hose (J).
I
Front Side of Battery Pack
J
C11. Remove the LH/RH rear seat assembly (K).
Refer to Shop Manual:
• Body (Interior / Exterior / Electrical) >
Rear Seat > Rear Seat Assembly >
Removal and Installation
TSB #: 23-01-069G
LH
K
Page 10 of 17
SUBJECT:
RH
K
C12. Remove the rear door LH/RH scuff trim (L).
Refer to Shop Manual:
• Body (Interior / Exterior / Electrical) >
Interior Trim > Door Scuff Trim >
Removal and Installation
L
C13. Loosen the LH/RH bolts (M) and remove the
rear seat belt lower anchor.
M
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SUBJECT:
C14. Remove the seatback tilt cables (N) and
separate the flow carpet.
N
N
C15. Loosen the LDC cable fixing bolt (O),
disconnect the cable, and then loosen the two
(2) ICCU bolts (P).
P
Tightening Torque:
Bolt O:
lb-ft
6.5
lb-in
78
N.m
8.8
O
P
Bolt P:
lb-ft
7.3
lb-in
87
N.m
9.8
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SUBJECT:
C16. Disconnect the ICCU AC connector (Q).
Q
C17. Disconnect the ICCU DC connector (R).
R
Disconnect the ICCU signal connector (S).
S
C18. Remove the LDC plus (T) after loosening the
mounting bolts.
Tightening Torque:
T
lb-ft
6.2
lb-in
74
N.m
8.4
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SUBJECT:
C19. Disconnect the coolant tube quick connectors
(U).
U
C20. Loosen the two (2) ICCU mounting bolts (V)
and disconnect the coolant hoses.
V
Tightening Torque:
lb-ft
18
N.m
25
V
C21. Remove the ICCU assembly (W) and replace
it with a new one.
W
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SUBJECT:
C22.
STUI
Using STUI, take a photo of the
installed new ICCU with the last 6 digits
of the VIN and the date of repair on a
piece of paper.
EXAMPLE
Upload the photo to STUI.
C23. Install all removed parts in the reverse order of
removal.
NOTICE
•
Be sure to install all components
according to specified torques.
•
Be careful not to drop any
components, as this may cause
internal damage.
C24. Refill the motor cooling system with coolant
and then fully bleed out air using the GDS
diagnostic tool.
NOTICE
Do NOT reuse coolant that was drained
from the vehicle. Doing this may bring
foreign substances and impurities into the
coolant system.
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SUBJECT:
D1.
Remove the Integrated Charge Control Unit
(ICCU) (A).
Refer to Shop Manual:
• Battery Control System > High
Voltage Charging System >
Integrated Charge Control Unit
(ICCU) > Removal
A
D2.
D3.
Remove the high voltage junction block upper
cover (B).
B
Loosen the mounting nuts, and remove the
high voltage ICCU fuse (C).
Tightening Torque:
lb-ft
3.6
lb-in
43
N.m
4.9
C
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SUBJECT:
D4.
After removing the bus bar, remove Loctite
residue with a screwdriver or other tool.
NOTICE
Any foreign substance in this area may
cause poor contact between terminals.
D5.
Install the supplied ICCU.
D6.
STUI
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.
EXAMPLE
Upload the photo to STUI.
D7.
Install all removed parts in the reverse order of
removal.
NOTICE
D8.
•
When installing the bus bar at the
fuse, apply Loctite.
•
Be sure to install all components
according to specified torques.
•
Be careful not to drop any
components, as this may cause
internal damage.
Refill the motor cooling system with coolant
and then fully bleed out air using the GDS
diagnostic tool.
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Page 17 of 17
SUBJECT: