Hyundai Sonata Plug-in Hybrid User manual

NEW THINKING.
NEW POSSIBILITIES.
Plug-in
Emergency Response Guide

Introduction
Sonata Plug-in Hybrid Identification
- General Vehicle Description
- Identifying a Hyundai Plug-in Hybrid
Sonata Plug-in Hybrid main systems
- Key Specifications
- Vehicle Components Location
- Vehicle Components
- Plug-in Hybrid System Operation
- Airbag system (SRS : Supplemental Restraint System)
Emergency procedures
- Initial response: Identify, Immobilize and Disable
- Extraction Operations
- Submersion
- Vehicle Fire
- High-Voltage Battery Damage and Fluid Leaks
Roadside Assistance
- Towing
- To Jump Start the Car
Contents
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Document Purpose
The purpose of this document is to familiarize emergency responders and the towing/roadside
assistance industry with the proper methods to handle the Hyundai Sonata Plug-in Hybrid in an
emergency situation. This guide offers a basic overview of key vehicle systems and provides
instructions for dealing with the different types of situations encountered by emergency
responders. The emergency response procedures for this vehicle are somewhat similar to a
conventional Sonata with additional information provided on dealing with the high-voltage
electrical system.
Vehicle Description
As with other plug-in hybrids, the Hyundai Sonata Plug-in Hybrid uses a conventional gasoline
powered internal combustion engine paired with a high-voltage electric motor to propel the
vehicle. The high-voltage battery is recharged by an external power source such as a charging
station through charging port. It is also recharged while the vehicle is being driven. This is
accomplished through the use of a generator that produces electricity during driving and braking.
Introduction 1

Sonata Plug-in Hybrid Identification 2
General Vehicle Description
The Hyundai Sonata Plug-in Hybrid is built on a conventional Sonata chassis and therefore the
four door sedan looks very similar to its conventional counterpart with a few notable exceptions.
The safest method is to assume that any Sonata you respond to is a Hybrid vehicle until proven
otherwise. Using the information provided in this section, responders will be able to differentiate
between the two.
Identifying a Hyundai Plug-in Hybrid vehicle
Plug-in Hybrid badge on Trunk and Blue Drive badge on side of Vehicle
The Hyundai Sonata Plug-in Hybrid can be easily identified by the Plug-in Hybrid badge located
on the trunk lid and the Blue Drive badge on the both sides of the vehicle, beside the charging
port cap on the left side of the vehicle.
Electrocution Risk
Badging can become hidden after a crash due to damage to the vehicle. Always be sure to
utilize additional methods if identification before determining there is no badge present.

Sonata Plug-in Hybrid Identification 3
VIN number
The Vehicle Identification Number (VIN) identifies the Plug-in Hybrid Vehicle with a “2” displayed
in the 6th position, as shown in the below drawing.
The VIN is punched on the floor under the passenger seat. The number 2 in the 6th character of
the VIN indicates that it is a Plug-in Hybrid with 2.0 gasoline engine.
XXXXX2XXXXXXXXX
6th position

Sonata Plug-in Hybrid Identification 4
Engine Compartment
Unlike the conventionally powered Sonata, the
Hybrid version has a plastic engine cover with
“hybrid” clearly shown on it.
Additionally, there are orange colored high-
voltage electrical cables in the engine
compartment.
Vehicle Underside
An orange colored cable covered by the under
cover is also visible on the underside of the
vehicle. This cable runs along the passenger
side from the rear of the vehicle to the engine
compartment.

Sonata Plug-in Hybrid Identification 5
Charging Port
The Charging Port is located on the front fender covered by the charging port cap and it has one
port for AC normal charging.
How to open the charging port
Unlock Charging Door in Emergency
1. Depress the brake pedal and apply the
parking brake.
2. Turn OFF all switches, move the shift lever to
P (Park), and turn OFF the vehicle.
3. Open the charging door by pressing it.
4. Open the charging inlet cover (1).
If the charging door does not open or the
charging cable is not disconnected, open the
hood and pull the emergency cable lightly as
shown left. The charging door will then open.

Sonata Plug-in Hybrid Identification 6
Plug-in Hybrid Vehicle Cluster Instrument Panel
The Plug-in Hybrid Vehicle Instrument Cluster Panel displays the Plug-in Hybrid vehicle specific
features that identify the Sonata as a plug-in hybrid vehicle. Also “plug-in hybrid” symbol is
located at the upper of the left side of the Instrument Cluster Penal.
: The Plug-in Hybrid Mode Gauge indicates the driving mode of the vehicle.
: The “Ready” Light indicates the vehicle is ready for driving.
: The charging cable indicator displays the cable is connected.
Charge Status Indicator
The battery charge status indicator, visible from
outside, at the center of the crash-pad, is
illuminated when the vehicle is charging.

Sonata Plug-in Hybrid main systems 7
Key Specifications
Item Plug-in Hybrid
Engine Displacement 2.0L GDI Hybrid Engine
Transmission Type 6speed Automatic Transmission
Fuel Tank Capacity
(U.S.gal / ℓ ) 14.5 / 55
Motor
Type Permanent Magnet Synchronous Motor
Max. Output (kW) 50
Max Torque (Nm) 205
Inverter Input Voltage (V) 240 ~ 413V
High Voltage
Battery
Type Lithium-ion polymer
Rated Voltage (V) 360
Capacity (Ah) /
Energy (kwh) 27.2 / 9.8
Number for Packs
(Cell / Module) 96CELL / 12MODULE

Sonata Plug-in Hybrid main systems
Vehicle Components Location
Hybrid Starter Generator
(HSG)
Electric AC Compressor
High-Voltage Cable
High-Voltage Battery Assembly
12V Auxiliary BatteryElectric Drive Motor
On Board Charger
(OBC)
OBC
On
-Board Charger :
Battery charging equipment (AC
→ DC)
HPCU
Hybrid
Power Control Unit
(Inverter + LDC + HCU)
LDC
Low Power DC
-DC Converter :
Charge 12V supplementary battery
Inverter
DC
→ AC (from battery to motor)
AC
→ DC (charge using regenerative braking)
Motor
When current flows through the coil.
It generates a
rotating magnetic field and generates motor torque.
High voltage battery
Supplies
and stores electric energy to traction motor.
HPCU
8