DTC P1A9096 Check For ICCU & Fuse Replacement & ICCU Software Update (Recall 021G)

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Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
RECALL 24-01-023G
MARCH 2024
GV60 (JW1 EV)
GV70 ELECTRIFIED
(JK1a EV)
G80 ELECTRIFIED
(RG3 EV)
DTC P1A9096 CHECK FOR ICCU & FUSE REPLACEMENT
& ICCU SOFTWARE UPDATE (RECALL 021G)
Description: Certain 2023-2024MY GV60 (JW1 EV), 2023-2024MY GV70 Electrified (JK1a EV), and
2023-2024MY G80 Electrified (RG3 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-5. The ICCU system
is to be checked via GDS for DTC P1A9096 and depending on the result, will involve either an ICCU
software update, or ICCU and High Voltage Fuse replacement.
Applicable Vehicles (Certain):
• 2023-2024MY GV60 (JW1 EV)
• 2023-2024MY GV70 Electrified (JK1a EV)
• 2023-2024MY G80 Electrified (RG3 EV)
Retailer must perform this Recall 021G 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.
 IMPORTANT
To avoid potential damage to Genesis EVs, Genesis EV repairs can only be performed by EV
certified Genesis retailers.
NOTICE
GROUP NUMBER
6 7 r DATE MODEL(S)
~ ~
Technical Service Bulletin
SUBJECT:
,–
TSB #: 24-01-023G Page 2 of 21
SUBJECT:
GDS Information:
ICCU
1096
JW ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
1097
JK EV ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
1098
RG3 EV ICCU SOFTWARE UPDATE, AND ICCU AND FUSE REPLACEMENT
(Secondary)
(*or use a later available event as listed in the GDS for ECM Update screen if one is available.)
Parts Information:
Integrated
Charge Control
Unit (ICCU)*
GV60 (JW1 EV)
2023MY
36400-1XCA0QQH
GV60 (JWI EV)
2024MY
36400-1XCA1QQH
GV70
ELECTRIFIED
(JK1a EV)
36401-1XDA0QQH
G80
ELECTRIFIED
(RG3 EV)
36401-1XBA0QQH
High Voltage
Fuse*
GV60 (JW1 EV) 375F2-GI040QQH
Order High Voltage Fuse in
Conjunction with the ICCU
GV70
ELECTRIFIED,
G80
ELECTRIFIED
(JK1a, RG3) EV
18790-00728QQH
Pink Coolant All 00232-19098 QTY. 1
*As needed, only if DTC is stored.
Do not install fuse alone without ICCU replacement. If vehicle is placed in Ready Mode after
replacing only the fuse and not the replacement ICCU, there is a possibility of DTC P1B77 Battery
PRA damage.
NOTICE
SUBJECT: DTC P1A9096 CHECK: ICCU & FUSE REPLACEMENT/ ICCU SOFTWARE UPDATE (RECALL 021G)
System Event# Description
Part Name Model Part Number Remarks
TSB #: 24-01-023G Page 3 of 21
SUBJECT:
Warranty Information:
ALL 41D044R0
DTC Check
and ICCU
Software
Update
0.4 M/H
36400-1XCA0QQH
(GV60)
36401-1XBA0QQH
(GV70 EV, G80 EV)
W11 ZZ3
GV60
(JW1 EV)
41D044R1
DTC Check,
and ICCU and
Fuse
Replacement
2.1 M/H 36400-1XCA0QQH
41D044R2
DTC Check,
and ICCU and
Fuse
Replacement
and software
update
2.4 M/H 36400-1XCA0QQH
GV70,GV80
Electrified
(JK1a EV,
RG3 EV)
41D044R3
DTC Check,
and ICCU and
Fuse
Replacement
3.3 M/H 36401-1XDA0QQH
41D044R4
DTC Check,
and ICCU and
Fuse
Replacement
and software
update
3.6M/H 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 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.
SUBJECT: DTC P1A9096 CHECK: ICCU & FUSE REPLACEMENT/ ICCU SOFTWARE UPDATE (RECALL 021G)
. Op. Nature Cause
Model Op. Code Operation r·1 me Causal Part Co d e Co d e
TSB #: 24-01-023G Page 4 of 21
SUBJECT:
Service Procedure:
Table of Contents:
A 7 DTC Check
B 7 – 11 ICCU Software Update
C 11 – 19 ICCU Replacement for GV60 (JW1 EV)
D 20 – 21
ICCU Replacement for GV70 Electrified (JK1a EV) and G80 Electrified
(RG3 EV)
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
STUI
TSB #: 24-01-023G Page 5 of 21
SUBJECT:
1. Turn ignition switch on and check for DTC’s using the GDS.
1) No DTC Found. Proceed with ICCU software upgrade for the applicable model following TSB.
2) DTC P1A9096 Confirmed. Follow the outline procedure in TSB to replace the ICCU & High
Voltage Fuse. Complete ICCU software upgrade if applicable for replacement ICCU.
Some replacement ICCU modules have been updated with improved logic prior to Dealer
delivery. The ICCU software update may, or may not, apply upon replacement. Dealer
must confirm the status of the replacement ICCU after installation.
i Information
TSB #: 24-01-023G Page 6 of 21
SUBJECT:
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 remedy ICCU part.
CAUTION
– 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
TSB #: 24-01-023G Page 7 of 21
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) 2023-2024MY – see section C
o GV70 Electrified (JK1 EV) 2023-2024MY – see section D
o G80 Electrified (RG3 EV) 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 the PRA damage.)
(Campaign Claim 2.1M/H for JW1 2023MY, JW1 2024MY or 3.3 M/H for JK1 EV, RG3 EV)
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.
NOTICE
TSB #: 24-01-023G Page 8 of 21
SUBJECT:
B1. Perform the ECU Update in Auto Mode.
Use the Auto Mode ID Check to verify the
ICCU ROM ID before updating the software.
B2. After the ECU Upgrade process shows 100%
complete, cycle the ignition key to OFF for at
least 10 seconds to reset the control unit.
B3.
Refer to TSB 15-GI-001 for additional
tablet-based Mobile GDS ECU update
information.
i Information
Take a screenshot of the ECU Update
Complete screen using your particular
tablet’s screenshot save method and
upload to STUI.
STUI
EXAMPLE
TSB #: 24-01-023G Page 9 of 21
SUBJECT:
B4.
B5.
After upgrade, remove power connector of
indoor fuse box, and reconnect it after 5
seconds. Alternately remove the battery
negative from the terminal and reconnect it
after 5 seconds, retightening.
Perform “Fault Code Search” for all
systems/modules and clear any DTCs that
may have resulted from the software upgrade.
B6. Start the vehicle in Ready mode to confirm
proper operation of the vehicle.
JK1a and RG3 Location of
connector
JW Location of connector
TSB #: 24-01-023G Page 10 of 21
SUBJECT:
ROM ID Information Table: Event #1096
JW1
(23MY)
ICCU
36401-1XCA0
EJW1E1-IDS02R000
EJW1E3-IDS09R000
EJW1E1-IDS03R000
EJW1E1-IDS04R000
EJW1E1-IDS05R000
EJW1E3-IDS06R000
EJW1E3-IDS07R000
JW1
(24MY)
36401-1XCA1 EJW1E4-IDS03R000 EJW1E4-IDS05R000
ROM ID Information Table: Event #1097
JK1a EV ICCU 36401-1XDA0
EJK1E1-IDS01R000
EJK1E3-IDS06R000
EJK1E1-IDS02R000
EJK1E3-IDS03R000
EJK1E3-IDS04R000
ROM ID Information Table: Event #1098.
RG3 EV ICCU 36401-1XBA0
ERG3E1-IDS01R000
ERG3E3-IDS09R000
ERG3E1-IDS02R000
ERG3E1-IDS51R000
ERG3E1-IDS04R000
ERG3E1-IDS05R000
ERG3E3-IDS06R000
ERG3E3-IDS07R000
TSB #: 24-01-023G Page 11 of 21
SUBJECT:
Manual Mode Passwords:
1096
JW ICCU 36401-1XCA0 (23MY) 1316
JW ICCU 36401-1XCA1 (24MY) 1326
1097 JK EV ICCU 36401-1XDA0 (23-24MY) 1317
1098 RG3 EV ICCU 36401-1XBA0 (23-24MY) 1318
C1. Disconnect the auxiliary 12V battery negative
(–) terminal (A).
A
TSB #: 24-01-023G Page 12 of 21
SUBJECT:
C2. Disconnect the high voltage cut-off switch (B)
in the direction of the arrow.
C3. Open the coolant reservoir tank cap (C) to
release pressure.
C4. Raise the vehicle on a lift.
Loosen the rear undercover bolts and remove
the cover (D).
Tightening Torque:
lb-ft 6.5
lb-in 78
N.m 8.8
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
D
C
B
TSB #: 24-01-023G Page 13 of 21
SUBJECT:
C5. Disconnect the ICCU high voltage connector
(E).
C6. Loosen the 4 bolts and remove the ICCU high
voltage connector assembly cover (F).
Tightening Torque:
C7. Using a T3 Hex bolt wrench, unscrew the
three (3) hex bolts and remove the ICCU fuse
cover (G).
Tightening Torque:
lb-ft 7.3
lb-in 87
N.m 9.8
lb-ft 2.2
lb-in 26
N.m 2.9
E
F
G
TSB #: 24-01-023G Page 14 of 21
SUBJECT:
C8. 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. Disconnect the rear coolant hose (I) and front
coolant hose (J).
Insert an air gun into the rear coolant hose (I)
to blow out internal coolant of the ICCU as
shown in the photo.
Then, the ICCU coolant will be drained
through the front coolant hose (J).
lb-ft 3.7
lb-in 44
N.m 4.9
H
Rear Side of Battery Pack
I
J
Front Side of Battery Pack
TSB #: 24-01-023G Page 15 of 21
SUBJECT:
C10. Remove the Rear seat assembly.
Refer to Shop Manual:
• Body (Interior / Exterior / Electrical) >
Rear Seat > Rear Seat Assembly >
Removal and Installation
C11. Remove the rear door LH/RH scuff trim.
Refer to Shop Manual:
• Body (Interior / Exterior / Electrical) >
Interior Trim > Door Scuff Trim >
Removal and Installation
C12. Loosen the LH/RH bolts (M) and remove the
rear seat belt lower anchor.
M
TSB #: 24-01-023G Page 16 of 21
SUBJECT:
C13. Remove the LDC cable fixing bolt (O),
disconnect the cable, and then loosen the two
(2) ICCU bolts (P).
Tightening Torque:
Bolt O:
Bolt P:
C14. Disconnect the ICCU AC connector (Q).
lb-ft 6.5
lb-in 78
N.m 8.8
lb-ft 7.3
lb-in 87
N.m 9.8
P
P
O
Q
TSB #: 24-01-023G Page 17 of 21
SUBJECT:
C15. Disconnect the ICCU DC connector (R).
Disconnect the ICCU signal connector (S).
C16. Remove bolt (T) securing the LDC to the
ICCU.
Tightening Torque:
C17. Place absorbent mat prior to disconnecting the
coolant tube quick connectors (U).
lb-ft 6.2
lb-in 74
N.m 8.4
R
S
T
U
TSB #: 24-01-023G Page 18 of 21
SUBJECT:
C18. Loosen the two (2) ICCU mounting bolts (V).
Tightening Torque:
C19. Remove the ICCU assembly (W) and replace
with the updated part.
lb-ft 18
N.m 25
V
V
W
TSB #: 24-01-023G Page 19 of 21
SUBJECT:
C20.
C21. Install all removed parts in the reverse order of
removal.
C22. Refill the motor cooling system with coolant
and then fully bleed out air using the GDS
diagnostic tool.
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.
Upload the photo to STUI.
STUI
Do NOT reuse coolant that was drained
from the vehicle. Doing this may bring
foreign substances and impurities into the
coolant system.
NOTICE
• Be sure to install all components
according to specified torques.
• Be careful not to drop any
components, as this may cause
internal damage.
NOTICE
EXAMPLE
TSB #: 24-01-023G Page 20 of 21
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
D2. Remove the high voltage junction block upper
cover (B).
D3. Loosen the mounting nuts, and remove the
ICCU fuse (C).
Tightening Torque:
lb-ft 3.6
lb-in 43
N.m 4.9
A
B
C
TSB #: 24-01-023G Page 21 of 21
SUBJECT:
D4. After removing the fuse carefully clean the
fuse mating surafce prior to installation.
D5. Install the replacment part ICCU.
D6.
D7. Install all removed parts in the reverse order of
removal.
D8. Refill the motor cooling system with new
coolant and then fully bleed out air using the
GDS diagnostic tool.
Do not reuse the coolant discharged from the
vehicle. (When coolant is reused, foreign
substances/impurities may be introduced.)
NOTICE
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
EXAMPLE
Any foreign substance in this area may
cause poor contact between terminals.
NOTICE
• When installing the fuse apply low
strength thread locker.
• Be sure to install all components
according to specified torques.
• Be careful not to drop any
components, as this may cause
internal damage.
NOTICE

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