2022-2023 Hyundai Ioniq ICCU Fault DTC P1A9096

Hyundai has initiated Service Campaign 997 to address a potential issue affecting certain 2022-2023 Hyundai Ioniq 5 (NE1) and 2023 Hyundai Ioniq 6 (CE1) vehicles. This campaign focuses on a condition that can lead to low 12V auxiliary battery charging due to a fault in the Intelligent Charging Control Unit (ICCU).

When this Hyundai Ioniq ICCU fault occurs, it can trigger Diagnostic Trouble Code (DTC) P1A9096, identified as a "DC/DC Converter Input Voltage Sensor Fault." This issue may cause the vehicle to enter a reduced power mode and display various critical warnings to the driver.

Symptoms Owners May Experience

Owners of affected Hyundai Ioniq vehicles might notice several indicators of this issue. The primary symptom is low 12V auxiliary battery charging. When the fault is active, the vehicle may enter a reduced power mode, limiting its performance.

Additionally, drivers may observe various warning lights illuminating on the dashboard. An audible chime will sound, and large messages will appear in the instrument cluster, instructing the driver to "stop the vehicle." If you experience these symptoms, it is crucial to address the issue promptly.

Fault Codes / DTCs

This service campaign specifically targets two Diagnostic Trouble Codes (DTCs):

• P1A9096: "DC/DC Converter Input Voltage Sensor Fault" – This is the primary code associated with the ICCU fault and low 12V auxiliary battery charging.
• P1B77: This code can be triggered if a fuse is incorrectly replaced before the ICCU, leading to damage to the battery PRA (Power Relay Assembly).

Diagnosis and Trigger Conditions

When a vehicle affected by Service Campaign 997 is brought to a dealer, the first step is a thorough inspection. This inspection will determine if DTC P1A9096 is present. The repair process varies based on the inspection results:

• If the vehicle passes the inspection and DTC P1A9096 is not found, only a software update for the ICCU is required.
• If the vehicle does not pass the inspection and DTC P1A9096 is present, the ICCU will need to be replaced. After ICCU replacement, the fuse will be inspected; if it is found to be blown, it will also be replaced.

Important Warnings for Owners

Hyundai has issued several critical warnings regarding this service campaign:

• Certified Dealers Only: This service campaign can only be performed by certified IONIQ Hyundai dealers. Non-certified dealers may not be reimbursed for the work.
• Do Not Drive with Fault: If your vehicle experiences low battery charging, reduced drive power, warning lights, an audible chime, and messages instructing you to "stop the vehicle," immediately stop your vehicle and have it towed to the nearest Hyundai dealer. Do not attempt to drive the vehicle until the repair has been applied.
• No Interim Repair: Dealers are instructed not to reassemble the vehicle with an affected ICCU and send the customer away, nor to simply replace the ICCU fuse without replacing the ICCU itself.
• Fuse Replacement Order: Never install a fuse before the ICCU is replaced as this will cause damage to the battery PRA and trigger DTC P1B77.

Repair Procedure Summary

The repair for the Hyundai Ioniq ICCU fault under Service Campaign 997, as detailed in Technical Service Bulletin (TSB) 23-01-060H, involves a diagnostic and repair sequence:

1. DTC Check: The technician will first check for DTC P1A9096.
2. Software Update: If the vehicle passes inspection and DTC P1A9096 is not present, an ICCU software update will be performed.
3. ICCU and Fuse Replacement: If the vehicle fails inspection and DTC P1A9096 is present, the Integrated Charging Control Unit (ICCU) will be replaced. Following ICCU replacement, the fuse will be inspected. If the fuse is found to be blown, it will also be replaced. It is critical that the fuse is only installed after the ICCU has been replaced to prevent damage and DTC P1B77.

Required Parts

For vehicles requiring ICCU replacement, specific parts are needed:

• 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-G1040QQH (to be ordered with an ICCU, but only installed if confirmed blown after ICCU replacement).
• Coolant (LLC-10): Part Number 00232-19098 (Pink coolant, up to 1 Gallon, reimbursed when ICCU replacement is required).

Owner Action and What to Expect

Owners of affected 2022-2023 Hyundai Ioniq 5 and 2023 Hyundai Ioniq 6 vehicles will be notified via First Class Mail in August 2023. If you experience symptoms related to the Hyundai Ioniq ICCU fault or DTC P1A9096, you should contact a certified Hyundai dealer to schedule an inspection.

The inspection and any necessary repairs, whether a software update or ICCU/fuse replacement, will be performed at no cost to you. If your vehicle requires ICCU replacement, a Service Rental Vehicle (SRC) or other alternative transportation may be provided due to the repair duration and potential need to order parts. If you have previously paid for a repair related to this condition out-of-pocket, you may be eligible for reimbursement by filing a claim with Hyundai Motor America.