2022-2023 Hyundai Ioniq ICCU Fault P1A9096 TSB

Hyundai has released Technical Service Bulletin (TSB) 23-01-060H, also identified as Service Campaign 997, to address a specific condition affecting certain 2022-2023 Hyundai Ioniq 5 (NE1) and 2023 Hyundai Ioniq 6 (CE1) vehicles. This bulletin details a potential problem with the Integrated Charge Control Unit (ICCU) that can lead to low 12V auxiliary battery charging and trigger a specific diagnostic trouble code.

This TSB provides comprehensive instructions for Hyundai certified dealers to diagnose and rectify the Hyundai Ioniq ICCU fault P1A9096, ensuring proper vehicle operation and battery charging.

Important Warnings for Owners and Technicians

Hyundai has issued several critical advisories regarding this service campaign:

• Dealers are required to perform this Service Campaign on all affected vehicles before customer retail delivery and whenever an affected vehicle is in the shop for any maintenance or repair. Dealers must use the "Vehicle Information" screen via WEBDCS to identify open campaigns.
• This service campaign can only be performed at certified IONIQ Hyundai dealers.
• CAUTION: Do not install fuse before ICCU replace. DTC P1B77 Battery PRA damage will occur.
• CAUTION: Never at first just replace ICCU fuse without replacing the ICCU together. It will cause DTC P1B77 PRA damage.
• The ICCU software update is a lengthy process. The 12V battery must be at a good charge level (above 60% SOC). If the vehicle experienced the DTC P1A9096 incident, it is more likely that the 12V battery will be low. Attach a battery charger to maintain the 12V battery during the update.
• If the voltage is below 12 volts, as indicated by the GDS warning "Warning! lower Battery Voltage. BATTERY VOLTAGE: 10.8", run the vehicle for at least 30 minutes to achieve an adequate battery state of charge. Cycle the ignition OFF/ON before retrying the ECU update.
• CAUTION: ONLY PERFORM THIS SECTION AFTER REPLACING THE ICCU. Do not install fuse before the ICCU. DTC P1B77 EV Battery PRA damage will occur.
• CAUTION: ONLY REPLACE THE FUSE IF FOUND TO BE BAD (BLOWN/OPEN).
• Avoid using a power driver to remove and install bolts during fuse replacement. Use hand tools only. There can be difficulty removing the fuse, which may include nuts of the fuse holder falling back into the battery.

Symptoms

Owners of affected 2022-2023 Hyundai Ioniq 5 and 2023 Hyundai Ioniq 6 vehicles may observe the following symptoms related to the Hyundai Ioniq ICCU fault P1A9096:

• Low 12V auxiliary battery charging.
• The vehicle may enter a reduced power mode.
• Various warning lights may illuminate on the instrument cluster.
• An audible chime may sound.
• Large messages will appear in the vehicle's instrument cluster, instructing the driver to stop the vehicle.

Fault Codes / DTCs

The primary diagnostic trouble code associated with this issue is:

• P1A9096: "DC/DC Converter Input Voltage Sensor Fault"

Another related DTC mentioned in the TSB is:

• P1B77: Indicates Battery PRA damage, which can occur if the fuse is incorrectly installed before the ICCU.

Diagnosis and Trigger Conditions

The condition is triggered by an ICCU fault that affects the 12V auxiliary battery charging. Diagnosis involves checking the ICCU system for the presence of DTC P1A9096, either as an active or history code, using the GDS (Global Diagnostic System).

Repair Procedure Summary

The repair procedure for the Hyundai Ioniq ICCU fault P1A9096 follows a specific flowchart:

1. DTC Check: A technician will perform an All Fault Search using the GDS.
2. P1A9096 Evaluation: The ICCU system is checked for DTC P1A9096.
   • If P1A9096 is NOT found: An ICCU software update is performed. If any other DTCs are present, they must be diagnosed and repaired according to the shop manual before the ICCU update.
   • If P1A9096 IS found: The ICCU is replaced, followed by an inspection and potential replacement of the ICCU fuse. The fuse is only replaced if it is confirmed to be blown or open.

ICCU Software Update

This involves ensuring the 12V battery is adequately charged, connecting a battery charger, and then performing the update in Auto Mode using the GDS. After the update, the ignition key must be cycled to OFF for at least 10 seconds to reset the control unit. A screenshot of the successful update completion must be uploaded to the STUI system.

• Ioniq 5 (NE1) ICCU Event 1001: NE1 ICCU OVER-CURRENT DIAGNOSTIC ENHANCEMENT UPGRADE (Manual Mode Password: 1384)
• Ioniq 6 (CE1) ICCU Event 1005: CE1 ICCU OVER-CURRENT DIAGNOSTIC ENHANCEMENT UPGRADE (Manual Mode Password: 1331)

ICCU Replacement

Replacing the ICCU is a multi-step process that requires careful handling of high-voltage components and coolant. Key steps include:

• Shutting off the high voltage circuit and allowing capacitors to discharge.
• Draining the motor coolant.
• Removing various interior components to access the ICCU (rear seat assembly, luggage side trim for Ioniq 5; rear seat cushion cover, rear wheel house trim for Ioniq 6).
• Disconnecting the ICCU's electrical connectors (AC, DC, signal, ground) and coolant tubes.
• Removing the old ICCU and installing the new one.
• Refilling and bleeding the motor cooling system.
• Documenting the new ICCU installation with a photo including the VIN and repair date.

EV Battery ICCU Fuse Inspection and Replacement

This procedure is performed only after the ICCU has been replaced. It involves:

• Shutting off the high voltage circuit and removing the rear under cover.
• Disconnecting the ICCU high voltage connector and removing its cover.
• Removing the ICCU fuse cover.
• Using a multimeter to check the fuse's resistance. A resistance less than 1.0 ohm indicates a good fuse, and it should NOT be replaced. A resistance greater than 1.0 ohm or an "OL" reading indicates a blown or open fuse, which must be replaced.
• Carefully removing the old fuse using hand tools to prevent nuts from falling into the battery compartment, and then installing the new fuse.

Required Tools or Parts

Technicians will require specific parts for this repair:

• Integrated Charge Control Unit (ICCU):
  • For Ioniq 5 (NE1): Part Number 36400-1XAA0QQH
  • For Ioniq 6 (CE1): Part Number 36400-1XEA0QQH
• Fuse: Part Number 375F2-GI040QQH (to be ordered with the ICCU, but only installed if the original fuse is confirmed blown/open).
• Coolant (LLC-10): Part Number 00232-19098 (Pink coolant, up to 1 Gallon).

Software updates for the ICCU will update the ROM ID to ENE1E3-IDS11R000 for Ioniq 5 (from various older versions) and ECE1E3-IDS03R000 for Ioniq 6 (from ECE1E3-IDS02R000).

Owner Action

If you own a 2022-2023 Hyundai Ioniq 5 or 2023 Hyundai Ioniq 6 and experience symptoms such as reduced power, warning lights, or messages instructing you to stop the vehicle, or suspect a Hyundai Ioniq ICCU fault P1A9096, you should contact a certified IONIQ Hyundai dealer. This service campaign is performed free of charge. The warranty operation codes are 30D073R0 for software updates (0.4 M/H) and 30D073R1 for ICCU replacement and fuse inspection (2.1 M/H).

NHTSA ID: 10240085