DTC P1A9096 Check For ICCU & Fuse Replacement & ICCU Software Update (Recall 257)

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Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
Technical Service Bulletin
GROUP
NUMBER
RECALL
24-01-023H
DATE
MODEL(S)
MARCH 2024
IONIQ 5 (NE1) IONIQ 6 (CE1) IONIQ 5 (NER) ROBOTAXI
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT
& ICCU SOFTWARE UPDATE (RECALL 257)
Description: Certain 2022-2024MY IONIQ 5 (NE1) & 2023-2024MY IONIQ 6 (CE1) & IONIQ 5 RoboTaxi (NER) 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):
• 2022-2024MY IONIQ 5 (NE1)
• 2023-2024MY IONIQ 6 (CE1)
• IONIQ 5 ROBOTAXI (NER)
GDS Information: System Event # Description
ICCU
1093*
NE1 ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
ICCU
1094*
CE1 ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
ICCU
1095*
NER ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
SUBJECT:
Vehicle repairs related to safety recalls are critically important and must be performed properly in accordance with TSB procedures. Review this bulletin in its entirety prior to beginning any repair work. As required by federal law, dealers must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers must also perform all open recalls on used vehicles, demo, and rental vehicles prior to placing them into customer use and whenever an affected vehicle is in the shop for any maintenance or repair. Access the “Vehicle Information” screen via WebDCS to identify open recalls.
 IMPORTANT
To avoid any potential damage to IONIQ vehicles, this recall can only be performed at IONIQ certified dealers. certified Genesis retailers.
NOTICE
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 2 of 18
SUBJECT:
SUBJECT
(*or use a later available event as listed in the GDS for ECM Update screen if one is available.)
Parts Information: Part Name Model Part Number Remark
Integrated Charge Control Unit (ICCU)
IONIQ 5
(NE1) 22-24MY
36400-1XAA0QQH
As needed only if DTC P1A9096 stored:
IONIQ 6
(CE1) 23-24MY
36400-1XEA0QQH
IONIQ 5 ROBOTAXI (NER)
36400-1XMA0QQH
Fuse**
Both
375F2-GI040QQH
Order High Voltage Fuse in
Conjunction with the ICCU
**CAUTION: Do not install fuse before ICCU replacement. DTC P1B77 Battery PRA damage will occur.
Coolant
Both
00232-19098
Pink coolant. Up to 1 Gallon.
Warranty Information: MODEL OP CODE OP NAME CAUSAL PART OP TIME NATURE CAUSE
IONIQ 5 (NE1) &
IONIQ 6
(CE1) & IONIQ 5 RoboTaxi (NER)
41D043R0
DTC CHECK AND ICCU SOFTWARE UPDATE
36400-1XAA0QQH (IONIQ 5)
36400-1XEA0QQH
(IONIQ 6) 364600-1XMA0QQH (IONIQ 5 ROBOTAXI) (NER)
0.4 M/H
W11
ZZ3
41D043R1
DTC CHECK, ICCU REPLACE AND FUSE INSPECTION
2.1 M/H
41D043R2
DTC CHECK, ICCU REPLACE AND FUSE INSPECTION AND ICCU SOFTWARE UPDATE
2.4 M/H
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 recall 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.
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 3 of 18
SUBJECT:
SUBJECT:
Service Procedure:
Table Of Contents: Section Pages Description
A
4
DTC CHECK
B
5-7
ICCU SOFTWARE UPDATE
C
8-11
ICCU REPLACEMENT FOR THE IONIQ 5 (NE1) & IONIQ 5 ROBOTAXI (NER)
D
11-15
ICCU REPLACEMENT FOR THE IONIQ 6 (CE1)
E
16-18
EV BATTERY ICCU FUSE INSPECTION
Service Procedure Flow:
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation Policy for requirements.
STUI
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 4 of 18
SUBJECT:
SUBJECT
A. DTC CHECK
A1.
A2.
Perform All Fault Search by GDS.
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) 2022-2024MY– see section C
o
IONIQ 5 ROBOTAXI (NER) – see section C (Contact Techline for Info)
o
IONIQ 6 (CE1) 2023-2024MY– see section D
•
Replace the Fuse – see section E.
(Notice: Replace the High Voltage Fuse in conjunction with the ICCU. Failure
to do so may result in PRA damage.)
(Campaign Claim 2.1 M/H)
If any other DTC or symptoms is found/stored, diagnose and repair per shop manual before performing the ICCU update.
It is critical when performing repairs to ensure the ICCU and High Voltage Fuse are replaced simultaneously. Damage to the PRA can occur if the High Voltage Fuse is replaced and the vehicle is placed in “Ready Mode” without the replacement ICCU part.
CAUTION
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 5 of 18
SUBJECT:
SUBJECT:
B. ICCU SOFTWARE UPDATE
– Remember the current ROM ID before upgrade just in case manual ECU upgrade would be performed.
– To verify the vehicle is affected, be sure to check the version of the vehicle’s control unit ROM ID
with reference to the ROM ID Information Table mentioned below before attempting to upgrade the
control unit software.
– After upgrade, remove power connector of indoor fuse box, and reconnect it after 5 seconds. Alternatively remove the battery negative terminal and reconnect it 5 seconds later. Afterwards, search DTC and clear them.
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 connect a battery charger to ensure an adequate battery state of charge for reliable update results. Turn ignition back on, and then retry the ECU update again.
NOTICE
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 6 of 18
SUBJECT:
SUBJECT
B1.
Perform the ICCU Update in Auto Mode.
Use the Auto Mode ID Check to verify the ICCU ROM ID before updating the software.
B2.
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. Perform “Fault Code Search” for all systems/modules and clear any DTCs that may have resulted from the software upgrade. B5. Start the vehicle in Ready Mode to confirm proper operation of the vehicle.
Take a screenshot of the ECU Update Complete screen using your particular tablet’s screenshot save method and upload to STUI.
STUI
EXAMPLE
Refer to TSB 15-GI-001 for additional tablet-based Mobile GDS ECU update information.
Information
i
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 7 of 18
SUBJECT:
SUBJECT:
ROM ID Information table:
VEHICLE SYSTEM ICCU P/No. ROM ID OLD NEW
Ioniq 5
(NE1 EV) 22-24MY
ICCU
36401-1XAA0
ENE1E1-IDS02R000
ENE1E1-IDS51R000
ENE1E1-IDS03R000
ENE1E1-IDS05R000
ENE1E1-IDS07R000
ENE1E1-IDS08R000
ENE1E1-IDS09R000
ENE1E3-IDS10R000 ENE1E3-IDS11R000
ENE1E3-IDS13R000
Ioniq 6
(CE1 EV) 23-24MY
ICCU
36401-1XEA0
ECE1E3-IDS02R000
ECE1E3-IDS03R000
ECE1E3-IDS06R000
Ioniq 5 RoboTaxi (NER)
ICCU
36401-1XMA0
ENE1E3RIDS01R000
ENE1E3RIDS02R000
ENE1E3RIDS04R000
Manual Mode Password Information:
ICCU Event 1093:
MENU PASSWORD
NE1 EV ICCU 36401-1XAA0
1313
ICCU Event 1094:
MENU PASSWORD
CE1 ICCU 36401-1XEA0
1314
ICCU Event 1095:
MENU PASSWORD
NER ICCU 36401-1XMA0
7788
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 8 of 18
SUBJECT:
SUBJECT
C. ICCU REPLACEMENT FOR THE IONIQ 5 (NE1) & IONIQ 5 ROBOTAXI (NER)
C1.
C2.
C3.
C4.
Shut off the high voltage circuit and wait 5 minutes for capacitors to discharge.
Drain the motor coolant.
Remove the rear seat assembly.
Remove the luggage side trim.
Refer to the shop manual:
Cooling System > Motor Cooling System > Coolant
Information
i
Refer to the shop manual:
Body (Interior and Exterior) > Rear Seat > Rear Seat Assembly
Information
i
Refer to the shop manual:
Body (Interior and Exterior) > Trunk Trim > Luggage Side Trim
Information
i
Wait for more than 5 minutes so that the capacitor in the high voltage system will be fully discharged. Battery Control System > High Voltage Shut-off Procedures
CAUTION
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 9 of 18
SUBJECT:
SUBJECT:
C5.
Remove the ground (A) after removing the mounting bolt.
Tightening Torque:
C6.
Disconnect the ICCU AC connector (B).
C7.
Disconnect the ICCU DC connector (C) and ICCU signal connector (D).
lb-ft 7
lb-in 84
N.m 9
A
B
C
D
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 10 of 18
SUBJECT:
SUBJECT
C8.
After loosening the mounting bolts, remove the LDC plus (E).
Tightening Torque:
C9.
Place absorbent mat under coolant tube connectors and disconnect the coolant tube quick connectors (F).
C10.
After removing the mounting bolts, remove the ICCU (G).
Torque Tightening:
lb-ft 7
lb-in 84
N.m 9
lb-ft 19
N.m 25
E
F
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 11 of 18
SUBJECT:
SUBJECT:
C11.
Install the replacement part 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.
D. ICCU REPLACEMENT FOR THE IONIQ 6 (CE1)
D1.
Shut off the high voltage circuit.
Drain the motor coolant.
Remove the rear seat cushion cover assembly.
EXAMPLE
Refer to the shop manual:
Battery Control System > High Voltage Shut-off Procedures
Information
i
Refer to the shop manual:
Cooling System > Motor Cooling System > Coolant
Information
i
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.
STUI
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 12 of 18
SUBJECT:
SUBJECT
Remove the rear wheel house trim.
Disconnect the V2L signal connector (A).and V2L extension connector (B).
D2.
After removing the bolts and nuts, remove the upper frame (C).
Torque Tightening:
lb-ft 19
N.m 25
B
A
Refer to the shop manual:
Body (Interior / Exterior / Electrical) > Rear Seat > Rear Seat Cushion Cover Assembly
Information
i
Refer to the shop manual:
Body (Interior / Exterior / Electrical) > Interior Trim > Rear Wheel House Trim
Information
i
C
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 13 of 18
SUBJECT:
SUBJECT:
D3.
Disconnect the ICCU AC connector (D).
D4.
After removing the bolt, Remove the LDC ground (E).
Torque Tightening:
D5.
Disconnect the ICCU DC connector (F) and ICCU signal connector (G).
lb-ft 10
N.m 13
D
F
G
E
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 14 of 18
SUBJECT:
SUBJECT
D6.
After removing the bolt, remove the LDC (+) (H).
Tightening Torque:
D7.
Place absorbent mat under the coolant tubes then disconnect the coolant quick connector (I).
D8.
After removing the bolt, remove the ICCU (J).
Torque Tightening:
lb-ft 7
lb-in 84
N.m 9
lb-ft 19
N.m 25
H
I
J
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 15 of 18
SUBJECT:
SUBJECT:
D9.
Install the replacement part 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.
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.
STUI
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 16 of 18
SUBJECT:
SUBJECT
E. EV BATTERY ICCU FUSE INSPECTION (Only applies after ICCU was replaced)
E1.
E2.
E3.
Shut off the high voltage circuit and wait 5 minutes for capacitors to discharge.
Remove the rear under cover.
Disconnect the ICCU high voltage connector (A).
E4.
Remove the ICCU high voltage connector assembly cover (B).
Tightening Torque:
lb-ft 8
lb-in 96
N.m 10
Refer to the shop manual:
Battery Control System > High Voltage Shut-off Procedures
Information
i
Refer to the shop manual:
Motor and Reduction Gear System > Rear Motor and Reduction Gear System > Rear Under Cover
Information
i
A
B
ONLY PERFORM THIS SECTION AFTER REPLACING THE ICCU.
Do not install fuse before the ICCU. DTC P1B77 EV Battery PRA damage will occur.
CAUTION
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SOFTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 17 of 18
SUBJECT:
SUBJECT:
E5.
Remove the ICCU fuse cover (C). Tightening Torque:
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.
3.7 lb-ft
lb-in 44.4
N.m 5.0
C
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.
CAUTION
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT ICCU SO FTWARE UPDATE – (RECALL 257)
TSB #: 24-01-023H Page 18 of 18
SUBJECT:
SUBJECT
E7.
Remove the ICCU fuse (D).
E8.
Install the supplied replacement part 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.
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.
See the below special instruction should this occur.
CAUTION
D

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