HYUNDAI SONATA HYBRID 2019 Workshop Manual

H40
Regeneration
The high-voltage battery is charged
up by the regenerative brake system. (Wheel ➞Battery)
Engine Brake
The engine braking is used to decel-
erate the vehicle. (Wheel ➞Engine)
Power Reserve
The engine is simultaneously used to
drive the vehicle and to charge up
the high-voltage battery. (Engine ➞Wheel & Battery)
■ Type A■ Type B
OLFH047772L/OLFH047216L
■ Type A■ Type B
OLFH047773L/OLFH047220L
DDRRIIVV IINN GG TT HH EE HH YY BBRRIIDD //PP LLUU GG--IINN HH YY BBRRIIDD VV EEHH IICC LLEE (( CC OO NNTT..))
■ Type A■ Type B
OLFH047774L/OLFH047224L

H41
Engine Generation/Motor Drive
The engine charges up the high-volt-
age battery. The motor power is used
to drive the vehicle. (Engine ➞Battery ➞Wheel)
Engine Generation/Regeneration
The engine and regenerative brake
system charges up the high-voltage
battery.
(Engine & Wheel ➞Battery)
Engine Brake/Regeneration
The engine braking is simultaneously
used to decelerate the vehicle and to
charge up the high-voltage battery. (Wheel ➞Engine & Battery)
■ Type A■ Type B
OLFH047775L/OLFH047226L
■ Type A■ Type B
OLFH047776L/OLFH047226L
■ Type A■ Type B
OLFH047777L/OLFH047218L

H42
High Voltage Battery System
OLFHQ014002K
OLFHQ014009L
■ HPCU (Hybrid Power Control Unit)
■ High Voltage Battery System Never touch orange colored or
high voltage labeled compo-
nents, including wires, cables,
and connections. When the insu-
lators or covers are damaged or
removed, severe injury or death
from electrocution may occur.
WARNING
While replacing the fuses in the
engine compartment, never
touch the HPCU. The HPCU car-
ries high voltage. Touching the
HPCU may result in electrocu-
tion, serious injury, or death.
WARNING
In the hybrid system, the hybrid
battery uses high voltage tooperate the motor and other
components. This high voltage
hybrid battery system can be
very dangerous. Never touch the
hybrid system. When you touch
the hybrid battery system, seri-
ous injury or death may occur.
WARNING
Do not pile up any items in an
area behind the high voltage
battery. In a crash, the battery
may become unstable, or its
performance may degrade.
Do not apply strong force nor
pile up any items above the
trunk. Such an attempt may
distort the high voltage battery
case, causing a safety problem
or degrading the performance.
(Continued)
CAUTION
SSAA FFEE TT YY PP RR EECCAA UU TTIIOO NNSS FF OO RR HH YY BBRRIIDD SS YY SSTT EEMM

H43
OLFHQ014007L
■ Drive Motor
Do not disassemble the high
voltage motor connector. The
high voltage motor connector
may contain residual high
voltage. Coming in contact
with high voltage may result
in death or serious injury.
Your vehicle's hybrid system
should only be inspected or
repaired by an authorized
HYUNDAI dealer.
WARNING
Do not disassemble or assem-
ble the high voltage battery
system. Doing so may result
in electric shock, causing
death or serious injury.
If you disassemble or assem-
ble hybrid system compo-
nents improperly, it may dam-
age the performance and reli-
ability of your vehicle.
If electrolyte comes in contact
with your body, clothes or
eyes, immediately flush with a
large quantity of fresh tap
water. Have your eyes exam-
ined by a doctor as soon as
possible.
WARNING (Continued)
Be careful when loading
inflammable liquid in trunk. Itcould cause operational and
safety degradation if the liq-
uid leaks and flows in high
voltage battery

H44
SSAA FFEE TT YY PP RR EECCAA UU TTIIOO NNSS FF OO RR HH YY BBRRIIDD SS YY SSTT EEMM (( CC OO NNTT..))
When the vehicle is paint baked,
do not bake over 30 minutes in
70°C (158°F) or 20 minutes in
80°C (176°F) degree.
Do not wash the engine compart- ment, using water. Water may
cause an electric shock and may
damage electronic components.
NOTICE
Never assemble or disassemble
the high voltage battery system.
If you assemble or disassem-
ble the high voltage battery
system, the durability and per-
formance of the vehicle may be
damaged.
When you want to check the
high voltage battery system,
have the vehicle checked and
inspected by an authorized
HYUNDAI dealer.
Do not touch the high voltage
battery and high voltage cable
connected to motor (orange
color). Severe burns and elec-
tric shock may occur. For your
safety, do not touch the cover
of electronic components and
electronic cable. Do not remove
the cover of electronic compo-
nents and electronic cable. In
particular, never touch the high
voltage battery system when
the hybrid system in operation.
It may result in death or serious
injury.
WARNING
Never use the package mod-
ules (high voltage battery,
inverter and converter) for any
other purpose.
Do not use an unauthorized
battery charger to charge the
high voltage battery. Doing so
may result in death or serious
injury.
Never place the high voltage
system near or in a fire.
Never drill into or strike the
package module. Otherwise, it
may be damaged. An electric
shock may occur, resulting in
serious injury or death.
WARNING

H45
Information
Gradual capacity reduction of the
high voltage battery.
The high voltage Battery capacity
gradually reduces with time and use.
This is natural characteristic of the
high voltage batteries. The extent at
which capacity is reduced changes
drastically depending on the environ-
ment(ambient temperature, etc.) and
usage conditions such as how the vehi-
cle is driven and how the high voltage
battery is charged. Reduction of the
high voltage battery capacity is not
covered under warranty.
Safety Plug
i
OLFHQ014005K
Never touch the safety plug. The
safety plug is attached to high
voltage hybrid battery system.
Touching the safety plug will
result in death or serious injury.
Service personnel should follow
procedures in service manual.
DANGER
(Continued)
Do not drop water or liquid on
to HPCU, HSG, motor and
fuses. The hybrid system com-
ponents are covered. If you
drop water or liquid on to
hybrid system compone nts, it
may result in electric shock.This hybrid vehicle uses the
hybrid battery system inverter
and converter to generate high
voltage. High voltage in the hybrid
battery system is very dangerous
and may cause severe burns and
electric shock. This may result in
serious injury or death.
For your safety, never touch,
replace, disassemble or remove
the hybrid battery system
including components, cables
and connectors. Severe burns
or electric shock may result in
serious injury or death when
you fail to follow this warning.
When the hybrid battery sys-
tem operates, the hybrid bat-
tery system can be hot. Always
be careful because burns or
electric shock may be caused
by high voltage.
(Continued)
WARNING

H46
SSAA FFEE TT YY PP RR EECCAA UU TTIIOO NNSS FF OO RR HH YY BBRRIIDD SS YY SSTT EEMM (( CC OO NNTT..))
High Voltage Battery Air Intake
Hybrid Vehicle
The high-voltage battery air intake is located on the bottom of the rear
seats. The air intake cools down the
high-voltage battery. When the high-
voltage battery air intake is blocked,
the high-voltage battery may be
overheated and the vehicle perform-
ance may become limited and set a
hybrid warning lamp. Do not obstruct
the air intake with any other objects.
Plug-in Hybrid Vehicle
The high-voltage battery air intake islocated on the left side of the rear
seats. The air intake cools down the
high-voltage battery.
When the high-voltage battery air
intake is blocked, the high-voltage
battery may be overheated and the
vehicle performance may become
limited and set a hybrid warning
lamp. Do not obstruct the air intake
with any other objects.
OLFP035100
Never clean the air intake of
the hybrid battery with a wet
cloth. If any water enters in
the air intake of the hybrid
battery, the hybrid battery
may cause an electric shock,
serious damage, injury ordeath.
The hybrid battery is com-
posed of lithium-ion polymer.
If the hybrid battery is improp-
erly handled, it is dangerous
to the environment. Also it
may cause electrical shock
and severe burns, resulting in
serious injury or death.
Do not spill liquid over the air
intake of the hybrid battery.
Doing so is very dangerous. It
may cause electric shock or
serious injury.
Do not cover the air intake with objects.
(Continued)
WARNING
OLFHQ014006K

H47
Information
Clean the air intake for the hybrid
battery with a dry cloth on a regular
basis.If an accident occursi
For your safety, do not touch
high voltage cables, connec-
tors and package modules.
High voltage components are
orange in color.
Exposed cables or wires may
be visible inside or outside of
the vehicle. Never touch the
wires or cables, because it
can cause an electrical shock,
injury or death may occur.
Any gas or electrolyte leakage
from your vehicle is not only
poisonous but also flamma-
ble. Upon witnessing one of
those, open the windows, and
remain a safe distance from
the vehicle out of the road.
Immediately contact an author-
ized HYUNDAI dealer and advise
them that a hybrid vehicle is
involved.
(Continued)
WARNING
(Continued)
Do not put any objects into
the air intake of the hybrid
battery. Doing so may cause
loss of air-intake volume to
the hybrid battery. When the
air intake is blocked with any
objects, immediately contact
your HYUNDAI dealer.
Never place a container of liq-
uid on or near the air intake. If
the liquid spills, the hybrid
battery located in the trunk
may be damaged.
Secure all loads in the trunk
to prevent them from being
tossed about before driving. If
a sharp or heavy loads
impacts or pierce the interior
trunk wall, the hybrid battery
system may be damaged,
deteriorating its performance.

H48
SSAA FFEE TT YY PP RR EECCAA UU TTIIOO NNSS FF OO RR HH YY BBRRIIDD SS YY SSTT EEMM (( CC OO NNTT..))
(Continued)
When the vehicle is severely
damaged, remain a safe dis-
tance of 15 meter (50 feet) or
more between your vehicle and
other vehicles/flammables.When a submersion in water
occurs:
When your vehicle is flooded in
water, a high-voltage battery
may cause shock or fires. Thus,
turn the hybrid system OFF, take
the key in your possession and
escape to a safe place. Never
attempt physical contact with
your flooded vehicle.
Immediately contact an author-
ized HYUNDAI dealer and advise
them that a hybrid vehicle is
involved.
WARNING
If a small scale fire occurs, use
a fire extinguisher (ABC, BC)
that is meant for electrical fires.
If it is impossible to extinguish
the fire in the early stage,
remain a safe distance from the
vehicle and immediately call
911. Also, advise them that a
hybrid vehicle is involved. If the fire spreads to the high
voltage battery, large amount ofwater is needed to put out the
fire. Using small amount of
water or fire extinguishers not
meant for electrical fires could
cause serious injury or death
from electrical shocks.
WARNING

H49
When the hybrid vehicle shuts off
When the high voltage battery is dis-
charged, when the 12-volt battery isdischarged, or when the fuel tank is
empty, the hybrid system may not
operate while driving. When the
Hybrid system does not operate, do
the followings:
1.Gradually reduce the vehiclespeed. Pull over your vehicle off
the road in a safe area.
2.Locate the shift lever in P (Park).
3. Turn ON the hazard warning flashers.
4.Turn OFF the Engine Start/Stop button, and try to start the hybrid system, while depressing the
brake pedal and pressing the
Engine Start/Stop button. 5.When the hybrid system still does
not operate, refer to "EMERGENCY
STARTING" in the chapter 6.
Before jump-starting the vehicle,
check the fuel level and the exact
procedure to jump start. For further
details, refer to "EMERGENCY
STARTING" in the chapter 6. When
the fuel level is low, do not attempt
to drive the vehicle only with the
battery power. The high voltage bat-
tery may be discharged, and the
hybrid system will turn OFF.