Hybrid Systems - HEV Powertrain Diagnosis
Group: GENERAL INFORMATIONNumber: 11-GI-005
Date: FEBRUARY 2011
Model: 2011 SONATA HEV
Subject
HYBRID ELECTRIC VEHICLE -
HEV POWERTRAIN DIAGNOSIS
DESCRIPTION:
Follow the Service Procedure to evaluate Hybrid Electric Vehicle powertrain operation.
SERVICE PROCEDURE:
1. Go to the following Sections to diagnose the symptoms listed below.
2. Compare the vehicle data to the data listed for each system. If the data is not correct, refer to the Sonata HEV Shop Manual for additional information on each system.
^ AUTOMATIC TRANSAXLE: Electric Oil Pump, Oil Pump Unit, A/T sensors
^ HYBRID CONTROL: 12v battery, 270v EV battery, Main Relay (PRA), cooling fan
^ HYBRID MOTOR: EV motor, Hybrid Starter-Generator (HSG), Hybrid PCU (HPCU), Electric Water Pump
1. DIAGNOSTIC TROUBLE CODE LIST:
^ Check for DTC's in the A/T, HCU, MCU and BMS menus. If DTC's are found, follow the procedure in the Sonata HEV Shop Manual and ETM for diagnosis.
NOTE:
Some DTC's will prohibit operation of the electric oil pump, which will result in 3rd gear "fail-safe" transmission operation.
2. 12V AUXILIARY BATTERY DATA:
^ Diagnose the 12V auxiliary battery using the Midronics tester or equivalent. Charge or replace the battery if necessary.
^ Compare the vehicle data to the data below. Confirm the following:
^ LDC output voltage is approximately 14.1v~14.5v
^ LDC Output Current is 1~125 A.
^ LDC Temperature is below 149°F (65°C)
^ LDC Power Derating Status is OFF.
NOTE:
If the LDC Temperature is above 167°F (75°C), the maximum output is derated to 60%. The LDC shuts down above 185°F (85°C).
3. HYBRID CONTROL UNIT (HCU) DATA:
^ Use GDS, Hybrid Control Unit (HCU) menu and Current Data to check the "EV Ready" status.
^ Compare the HCU inputs to the data below. If not, refer to the Sonata Shop Manual and diagnose the inputs.
NOTE:
"EV Ready" is not possible if the "12V Battery Voltage" is discharged.
4. BATTERY MANAGEMENT SYSTEM (BMS) DATA:
^ Use GDS, Battery Management System (BMS) menu and current data to check the hybrid battery. Compare the vehicle data to the data below. Confirm the:
^ State of Charge (SOC) is between 30~90%
^ Battery Maximum Temperature is below 131°F (55°C)
5. HYBRID STARTER-GENERATOR (HSG) DATA:
^ Use GDS, Motor Control Unit (MCU) menu and current data to check the HSG output with the gasoline engine running.
^ Compare the vehicle data to the data below. Confirm the:
^ Inverter DC Link Voltage is approximately 260~280V
^ Generator (HSG) Phase Current is 1~125 A.
^ Actual Generator Torque is 0~43 Nm.
NOTE:
The Generator (HSG) Resolver Offset should be 6.28 +/-.17 el.
NOTE:
A Resolver CAL Command of 4 indicates the Motor/HSG Resolver Calibration has not been completed.
6. MOTOR CONTROL UNIT (MCU) DATA - EV MOTOR PERFORMANCE:
^ Use GDS, MCU menu and current data to check the EV motor data while driving in the EV mode. Compare the vehicle data to the data below. Confirm the:
^ Inverter DC Link Voltage is approximately 260~280v
^ Actual Drive Motor Torque is 1~205 Nm
^ Drive Motor Phase Current (RMS value) is 1~245 Arms
^ Drive Motor Temperature is below 320°F (150°C)
^ MCU Temperature is below 165°F (74°C).
NOTE:
The MCU output is derated to 80% above 75°C and shuts down above 95°C.
NOTE:
The Drive Motor Resolver Offset should be 2.28 +/-.18 el.
NOTE:
A Drive Motor Resolver CAL Command of 4 indicates the Motor/HSG Resolver Calibration has not been completed.
7. AUTOMATIC TRANSMISSION DATA - ELECTRIC OIL PUMP:
^ Use GDS, A/T menu, current data to check Electric Oil Pump (EOP) speed in Park and "EV Ready" state.
^ If the EOP command RPM is below 400 rpm, diagnose the Oil Pump Unit (OPU) according to the Sonata HEV Shop Manual.
^ If EOP actual rpm is below 400 rpm, replace the Electric Oil Pump (see Electric Oil Pump replacement, Section 11).
NOTE:
If the Electric Oil Pump is not operating in Drive at a stop, the transaxle clutches cannot engage.
8. AUTOMATIC TRANSMISSION DATA - ENGINE CLUTCH:
^ Use GDS, A/T menu, current data to check the engine clutch status.
^ Drive the vehicle above 15 mph and 20% IPS.
^ Confirm the engine clutch shows "Lock" when:
^ Engine clutch solenoid is above 700 mA
^ Engine clutch command pressure is above 140 psi.
^ If not, the engine clutch is not functioning properly and the motor/transaxle assembly may need to be replaced.
NOTE:
Call Techline before replacing the EV motor/transaxle assembly.
9. CALIBRATION PROCEDURES: Refer to TSB 11-GI-003
^ Calibrate the E/C Fluid Pressure after replacing the HCU, engine, EV motor/transaxle assembly or fluid pressure sensor:
^ Use GDS, HCU menu, Option Treatment and E/C Fluid Pressure Calibration to relearn the engine clutch.
^ Calibrate the Motor/HSG Resolver after replacing MCU, EV motor or HSG,
^ Use GDS, HCU menu, Option Treatment and Motor/HSG Resolver Calibration.
10. APPENDIX: OIL PUMP REPLACEMENT:
1. Squeeze the tab and disconnect the connector above the oil pump.
2. Use a screwdriver to push the gray tab to the left.
3. Squeeze the tab and remove the connector for the fluid pressure switch.
4. Remove two bolts and one nut and remove the electric oil pump.
5. Confirm two 0-rings are installed on the case and one 0-ring on the electric oil pump and install the pump.
6. Go to Section 7, "Electric Oil Pump" and confirm the electric oil pump operates correctly.
WARRANTY INFORMATION:
Normal warranty applies.