Hyundai Ioniq 5 High Voltage failure - Battery removal

This is the continuation of my previous video regarding the ioniq 5 with high voltage system fault. If i still remember correctly the previous video that we cannot install the fuse because the nut fell inside the battery. In this video i got no choice but remove the battery assembly and disassemble it to replace the fuse holder. This is also my first time to remove the top cover of the high voltage battery. I hope you will enjoy this video and if you have some suggestions or questions let me know. Thank you for watching
This youtube channel is intended for informational purposes only. The jobs that you see on these videos are based on my knowledge and experience as a technician. Information provided through this youtube channel is not intended to serve as a substitute for your professional technician/manufacturer.
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Editing software: Animotica
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[@Horsecockbadger]

This us the only vid on KZbin of an actual dealer tech working repairing a fully electric car.

[@hyundaitech]

Thanks man hahaha

[@EV_OBD]

ICCU will be diagnosed and replaced in many vehicles now, after the latest service bulletin (KIA SC271): Voluntary Service Campaign - "ICCU software upgrade or ICCU assembly and fuse replacement". Thanks for this video!

[@oscarsegura451]

Just found your video. Appreciate the time you put into making this and showing us the process.

[@hyundaitech]

Glad it was helpful! Thank you

[@3dw3dw]

It was a good video. As a retired mechanic and an ioniq 5 owner, this video was very informative.

[@hyundaitech]

Thank you sir

[@ianrobins5501]

just came across your channel. very interesting and thank you for taking the time to document the ICCU issue. i have posted both ICCU videos on the Ioniq 5 and ev6 FB groups in the UK as there have been a number of ICCU failures recently so thought it would be of interest to the owners.

[@munirshafi2647]

My car has just gone into a UK dealership (Oxford) with the same issue after the 12v battery drained. They ordered a new battery and told me I’d have to pay for it (£186)and then after fitting it found out it was still not being charged by the system. Has my ICCU unit likely failed and will they still try to charge me something ? Car is 2.5 years old on a 71 plate, so obviously still in warranty.

[@Alex-yx4vd]

How cool was that! thanks for sharing.

[@soerenras111]

Just been through a ICCU replacement and also the fuse on the battery. The workshop managed to do it in only one day. So I was lucky, and got my ioniq 5 back very fast. Fine video!

[@heyramineni]

Are you from the US? I’m going through the same exact problem, started today.

[@njchang]

I’m in Canada and going through the same process now. I was told the update didn’t solve my issue and very few customers actually go through the whole replacement process. I was also told half a day of work once the parts come in.

[@EdBonds]

helpful video thanks, just having my iccu replaced at the moment

[@hyundaitech]

Nice

[@xvdd1]

Since I own an I5 I found this video interesting thank you. Just a minor observation I think if I was carrying out this procedure I would have used the coolant caps from the new ICCU to seal off the old ICCU hose connectors before removing it which should help limit coolant spillage.

[@hyundaitech]

Hehehe thats true, i did not think about that, and i think the coolant mess in this video was not that bad. Hahahha

[@xvdd1]

@@hyundaitech I know you cannot make an omelette without breaking eggs.

[@3dw3dw]

I tend to lean more toward the shop vac method, but that works too.

[@audvidmediavanbergen9534]

Thank you for sharing your video. I'm waiting for my own Ioniq 5 (to be delivered in may 2023) and came across the 12 volt charging issue in many forums. I hope that my Ioniq comes with the new ICCU and fuse already replaced. Otherwise I know what video I have to refer to!

[@hyundaitech]

Yup, i think they improve some stuff.

[@markferraro5250]

great job MARKO thanks

[@hyundaitech]

Thank you sir? You also work in hyundai?

[@garagesociety9907]

Great video Thanks

[@chuyengiaienotohyndaikia883]

You do very well I am a Hyundai repair technician from viet nam nice to meet you

[@hyundaitech]

Thanks man, nice to meet you too.

[@chuyengiaienotohyndaikia883]

@@hyundaitech where are you from

[@hyundaitech]

@@chuyengiaienotohyndaikia883 from canada sir.

[@chuyengiaienotohyndaikia883]

@@hyundaitech yes

[@neverstoplearning382]

Almost all the battery packs I have seen look the same, connected in series. What a stupid design, all that work for that silly connector. Great job mate. Welcome to the electric future.

[@hyundaitech]

Yup i was shaking my head when trying to figure out how i can install it without removing the battery. Hahahha but i still lost by the engineering design. Hahaha

[@pennyandian]

Yeah because ICE cars are designed to be so easy to service!

[@NoodlesExtraMSG]

Your channel should way more popular, EV infrastructure is lagging behind but its nice to know the Mechanics/Techs are knowledgable on the new cars. Is that scanner a Hyundai/Kia specific tool?

[@hyundaitech]

Hahhaa thanks. Yeah as for me i have no choice but to keep up the technology if i want to stay in this industry since everyday theres always new. And also for me to be more competitive hahaha. Yeah the scantool is for hyundai/genesis.

[@hybridsolutiondiagnostics]

Very interesting video... thanks for sharing 👋😎👋😎

[@hyundaitech]

Yup, just because of the fuse and that nut fell off i have to remove or disassemble the battery hahahha.

[@An_Engineers_Approach]

If your careful you can replace the fuse without dropping it the pack. I used a strong magnet on the back of the allen head socket to thread it back in there. Also please wear HV gloves once your in there.

[@hyundaitech]

The second vehicle i did the same fuse replacement and yeah i was careful. For the gloves, i was only handling side of 12 volt on that and im aware that its high voltage system. Thanks again

[@eugeneeom8109]

As hyundai EV technician, the way this guy works, pretty straight forward but lots of things ignored especially safety. Have to wear 1000v electrical safety gloves, barrier around vehicle(no one can enter inside except certified person), no vacuum test after he reseal the battery pack-it takes 3 hours. Well in terms of work, it fast but can't guaranty battery pack has sealed. Also there is coolant bleeding function in GDS but he didn't use it. Common problem in Hyundai battery pack is air trapped in battery pack corner and won't bleed out during process, so have to at least 3 times. Well hope you to follow this procedures to improve work qualities

[@hyundaitech]

Hi sir, yeah as i mention i think on the video unfortunately we dont have that special tools to do those process, i was showing in this video whats inside and what i replace for that fuse. And i think mention too that we need to send it to head office to do the vacuum or leak test. Anyway thanks for the input.

[@slepro]

Thanks for this video! It's very informative! You have a new subscriber now :)) Do you remember how long it took to receive the new ICCU part?

[@hyundaitech]

During this time it was like months, but i dont know now maybe the supply got improve. Thanks again

[@etiennebolduc838]

nice video

[@hyundaitech]

Thank you

[@lovingEV]

What an amazing and informative video which I'm sure took a lot of your own personal time to make and edit well done and thank you. Have sent to every Hyundai/kia service manager dealer here in my country Now for my own story on my Kia EV6 2021 ... It fails to charge on any AC charger but lucky for me it will charge on DC chargers without any issues .. Has no warning/battery lights on screen and drives perfectly also charges the 12v on the go. Dealer diagnosed ICCU replacement which I'm hoping is only that and not the fuse.. Wouldn't not be happy with battery being opened up Can you comment as to why the car drives and charges perfectly on DC

[@hyundaitech]

Thank you. For the DC charging, when it charges it goes straight to inverter and to your battery unlike level 2 charging it has to c9mmunicate to OBC (on board charger) which 1 unit with ICCU and from there goes to battery if im not mistaken. So in my opinion thats why you can still charge the vehicle with DC. Hope that helps.

[@lovingEV]

@@hyundaitech it does thank you for the reply

[@nickpiponides3501]

Hi Thanks again for a great video. I posted in part 1 that my I5 is at the dealership waiting for a new ICCU & fuse to be delivered. In your video, what made you need to install a new fuse housing? Was it because the holding nut fell off, or did anything break on the housing? Also, in hindsight, do you think you could've replaced the housing without dismantling the battery pack? Would it not wiggle out of that hole? I'm asking because I'm going to show your video to my service techs so they can know what to expect.

[@hyundaitech]

Thank you for liking my video, yes i replace tge housing because the nut fell off inside the battery, i think if i knew that the nut was design like that i think i would have more careful in removing that fuse. For the part they cannot give me the fuse onky it come with that fuse holder assy. Trust me i tried to remove it without removing the battery, but the more yoy squeeze the holder assy out the battery the more it will make damage on the wiring so i said to myself i wont risk that especially we are talking high voltage system. I dont know why design it like that maybe to have a proper seal of the battery system. Hope that helps

[@tomrossman9371]

Wow, there's some scary stuff right there! I hope that was covered by warranty.

[@hyundaitech]

Yup its all warranty hahaha.

[@bobsg35]

Months?

[@hyundaitech]

@@bobsg35 i think if im not mistaken the hybrid warranty components is different from the 5 years 100k km, tge last time i did warranty on a sonata hybrid they said 8 years 180k km, im not sure tho.

[@RobertHamilton59]

Great video! Thanks for posting. Have you seen any ICCU failures AFTER the software patch has been applied?

[@hyundaitech]

So far i didnt encounter that scenario yet. Did the update go thru successfully?

[@serio-usindustries448]

Did you have to open the battery the fuse holder nuts fell into the battery? Do the new fuse holders have nuts that don't fall out?

[@hyundaitech]

Yeah thats why i open the cover coz someone design it without a retainer on the nuts hahahha. Yeah the new fuse box has a retainer there, but i did one fuse from.another vehicle you just have to be very careful removing it and it will stay.

[@high-byte]

Hi. Tell me more about what's going on with the fuse nuts. I have the same problem, I don't want to remove the battery because of the fuse.

[@hyundaitech]

The nut thats holding the fuse doest have a holder in this earlier models of the battery, but what i heard from head office the newer vehicles and updated battery has a retainer for those nuts so that when removing the fuse it wont fall down.

[@dominikhejl5748]

nut falling into the battery. exactly same thing happened to me when i changed this fuse for the first time. but i put the nut back in easily, why did you change whole fuse case?

[@hyundaitech]

Well on thus video, this was there first issue, so i was advice from the head office to replaced the whole thing, coz the updated part has retainer for those nuts.

[@jarjarbinx79]

is the shield at the bottom glued to the main battery pack?

[@hyundaitech]

I think they are not glued coz of i correctly remember those small battery can be remove individually from the main battery case.

[@BigEightiesNewWave]

OMG horror episode, battery has to come out!

[@robertreynolds8092]

I do not know where you are located but I want you to work on my Ioniq 5!

[@hyundaitech]

Whats wrong with your vehicle? Im from toronto

[@robertreynolds8092]

@@hyundaitech It is running fantastic but someday...Not certain the dealers around here are properly trained yet.

[@hyundaitech]

@@robertreynolds8092 ahhh okay okay theres should be couple of guys in a dealer thats trained.

[@triplextriplexxx8225]

where did you buy gds tool from ?

[@hyundaitech]

We have provided scantool from hyundai, but if you want the same factory scantool you can check this website www.gitauto.com/Eng/Product/12gds_smart.aspx Thats our supplier for scantools.

[@michelleshimenosky8194]

Thanks for sharing! That was really 😎 cool. Is there a certification for EV mechanics in Canada?

[@hyundaitech]

Yes, its more on safety practices especially dealing with high voltage system.

[@Chande707]

how much would it be to replace the entire battery?

[@hyundaitech]

I think thats gonna be expensive, i dont know about the ioniq 5 but on kona i think the battery cost 20 grand if im not mistaken.

[@Chande707]

@@hyundaitech yes.. I think is new And low inventory will.jack up the price. That's why I'm learning toward GM Platform since a single cell can be exchanged

[@noisecloud2846]

how long was the customer without there car?

[@hyundaitech]

Long time i think 3-4 weeks because of waiting parts.

[@ewkplymi]

What a nightmare.

[@michaellippmann4474]

No kidding right? Not like a new Corvette that needed a motor repair and you have to drop the whole drive train out to access it? ALL new vehicles are complicated and require all sorts of major removals for repairs that in the past where simple...not exclusive to an electric vehicle. Mechanics these days have entirely different skill sets from mechanics in days of old. So not really a nightmare.

[@rwferr2]

A few months to get a fuse....

[@robertreynolds8092]

Mine just died with this exact malady.

[@GTRDRIVER1]

You forgot about the leak testing for battery and coolant system...

[@hyundaitech]

I mention in the video that either we send it to head office to do that procedure before releasing to customer but it ended up we did it after the special tools came.

[@davenone7312]

You should let your coworkers know when you're filming, so they don't curse on your video's.

[@hyundaitech]

Yeah , i will keep that in mind.

[@BigEightiesNewWave]

Imagine the poor fool who buys it after the warranty, it will be a paperweight.🤣

[@hyundaitech]

I guess the best thing they can do is lease the vehicle.

[@karate353]

U shouldn’t use ur protective gloves when u working in a live baterie and talk about the danger involved hyundai manufactures dont give security courses

[@BigEightiesNewWave]

Pathetic, none of this can be done at home by a consumer, like on an ICE vehicle. BEV is not the answer, it is a mess.

[@hyundaitech]

Yeah most ev repair work you really need to go to a shop

[@michaellippmann4474]

Lol...try repairing your new ICE vehicle...you think it is less complicated? If you do you are kidding your self...if anything they are way more complicated. ALL new vehicles are very complicated, even your basic cheapo econo box has systems on it that your back yard mechanic cannot do much with. Pretty much the only thing you are gonna do on your new ICE vehicle is change oil, filters and maybe plugs....that's it. Oh my Ioniq5 has none of those (except cabin air filter), my Toyota RAV4 has all tbose things and more to keep me busy in my fully equiped shop at home. Very happy to be driving a BEV they happen to be a big part of the answer...in my opinion of course and you are free to yours! 😂 Have a nice day! Mike