257/021G – Loss of Drive Power from Damaged Charging Unit – 2022-2024 Hyundai IONIQ 5, 2023-2024 IONIQ 6, Genesis GV60, Genesis GV70 “Electrified,” and Genesis GV80 “Electrified”

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March 15, 2024 NHTSA CAMPAIGN NUMBER: 24V204000

Loss of Drive Power from Damaged Charging Unit

A loss of drive power increases the risk of a crash.

 

NHTSA Campaign Number: 24V204000

Manufacturer Hyundai Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 98,878

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2022-2024 IONIQ 5, 2023-2024 IONIQ 6, Genesis GV60, Genesis GV70 “Electrified,” and Genesis GV80 “Electrified” vehicles. The Integrated Charging Control Unit (ICCU) may become damaged and stop charging the 12-Volt battery, which can result in a loss of drive power.

 

Remedy

Dealers will inspect and replace the ICCU and its fuse, as necessary. In addition, dealers will update the ICCU software. All repairs will be performed free of charge. Owner notification letters are expected to be mailed May 14, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 257/021G.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Hyundai has a Recall

Check if your Genesis has a Recall

 


Hyundai Recall Campaign 257/021G

Attachment A: Requested Chronology of Events Leading Up to Decision

 

October 2022 – March 2023

  • Beginning in October 2022, HMC began examining ICCU warranty returns from various markets and noted heat damage on the low-voltage converter field effect transistor(s) (“FET”) of the ICCU assemblies equipped in certain Hyundai and Genesis electric vehicles.
  • In January 2023, HMC began evaluating potential overcurrent modes in the ICCU in an attempt to replicate the FET failure(s) observed in examined warranty part returns.

 

April – September 2023

  • On April 24, 2023, NHTSA’s Office of Defects Investigation (“ODI”) notified NASO of certain VOQ’s received alleging a loss of motive power in a Hyundai IONIQ 5 vehicle located in the U.S. NASO held multiple discussions from April to May informing ODI of its analysis of field information and the findings of HMC’s investigation and ongoing replication testing.
  • On May 17, 2023, HMC conducted vehicle driving tests to study the potential loss of power following failure of the ICCU, specifically regarding the effects of low-voltage convertor fault(s) on vehicle mobility, warning signs that precede an ICCU fault, and driving time and range following an ICCU fault.  These tests were performed with the Korea Automobile Testing and Research Institute (“KATRI”).  The testing results indicated that the vehicle remains operational following a low-voltage convertor fault, resulting in multiple audible and visual warnings to the driver.  The results confirmed that if the vehicle continues to be driven while ignoring the warning symptoms, the vehicle will eventually lose all motive power.  The test results also confirmed that the onset of the fail-safe mode includes full motive power during the initial 22 minutes after ICCU fault detection, followed by five (5) stages of progressive warnings and gradual motive power limitations, providing a total cumulative drive time of up to 45 minutes in fail-safe mode.  Further examination of the test results confirmed that total drive time with access to motive power is dependent on several factors such as powered vehicle accessories, ambient conditions such as temperature and humidity, and road driving conditions such as curvatures and inclines.
  • On May 24, 2023, NASO held a video conference meeting with NHTSA to discuss updates to its investigation, including the results of HMC’s joint testing with KATRI.
  • On June 23, 2023, NHTSA issued an opening resume letter stating that formal investigation PE23-011 had been opened to investigate ICCU failures in certain model year 2022-2023 Hyundai IONIQ 5 vehicles manufactured by HMC for sale in the U.S.
  • On July 17, 2023, Hyundai launched service campaign SC997 to address the subject condition in affected Hyundai electric vehicles in the U.S. market.
  • On July 28, 2024, HMC performed a second test at the Hyundai-Kia Namyang Centre High-Speed Proving Ground using a Hyundai production test vehicle with multiple accessories activated. The results indicated 11 minutes of full motive power and 33 minutes of total vehicle operation following a low-voltage convertor fault, with multiple visual warnings and an audible chime, leading up to a complete vehicle stall condition.
  • On August 10, 2023, NASO submitted its first response to PE23-011 to the agency.
  • On September 21, 2023, Genesis launched service campaign SC907G to address the subject condition in affected Genesis electric vehicles in the U.S. market.
  • On September 26, 2023, NASO held a joint vehicle demonstration with HMC and members from NHTSA’s Vehicle Research and Testing Center (“VRTC”) at Hyundai’s Safety Test and Inspection Laboratory (STIL) in Michigan.  The results confirmed 10 minutes of full motive power and approximately 21 to 26 minutes of total vehicle operation leading up to a complete vehicle stall.  The test was performed with conditions representative of a “harsh” or “worst-case” scenario, including multiple vehicle accessories powered on and use of a test-track containing turns and inclines requiring driving maneuvers typically demanding increased 12-volt auxiliary power draw.  NASO and HMC also noted that test trials performed in advance of the joint session yielded results consistent with prior findings.
  • On September 27, 2023, NASO submitted its final response to PE23-011 to the agency, including its final assessment of the subject condition.

 

January – February 2024

  • On January 31, 2024, HMC informed NASO of its updated findings in its investigation. NASO’s Data Analysis (“DA”) team created a new case for reconsideration of the current service campaign and immediately escalated it to the Data Review Committee (“DRC”) on January 31, 2024.
  • On February 7, 2024, the DRC escalated the case to the Technical Review Committee (“TRC”) based on its preliminary analysis of field information. NASO’s TRC began analyzing and confirming field information, including an examination of the ongoing service campaign, related claim data, and accumulated results of prior testing performed by HMC.

 

March 2024

  • On March 8, 2024, HMA’s NASO convened its North America Safety Decision Authority (“NASDA”) for review of the TRC’s findings and recommendation.
  • ❖ In its review of the subject condition, the NASDA acknowledged that multiple, extensive operator warning(s) occur over an extended period of drive time, during which the vehicle initially retains full motive power before entering several stages of gradually reduced motive power, culminating in a loss of all motive power after a time period of 22-45 minutes. Although the NASDA concluded that the length of available drive time with sufficient mobility during fail-safe driving is reasonably sufficient for detection by vehicle occupants, and NASO’s investigation did not identify related any crashes or injuries, the NASDA decided to conduct a safety recall of affected Hyundai and Genesis vehicles in the U.S. and Canada out of an abundance of caution.

 

NASO has confirmed six hundred and eighteen (618) unique incidents in the U.S. from reports received beginning March 8, 2022, through March 5, 2024.   There are no crashes, injuries, or fatalities attributable to this condition in the U.S. 

 


DTC P1A9096 Check For Iccu & Fuse Replacement & ICCU Software Update (Recall 257)

 

DTC P1A9096 Check For ICCU & Fuse Replacement & ICCU Software Update (Recall 257)

 


DTC P1A9096 Check For ICCU & Fuse Replacement & ICCU Software Update (Recall 021G)

 

DTC P1A9096 Check For ICCU & Fuse Replacement & ICCU Software Update (Recall 021G)

 


11 Affected Products

Vehicles

MAKE MODEL YEAR
GENESIS GV60 2023-2024
GENESIS GV70 EV 2023-2024
GENESIS GV80 EV 2023-2024
HYUNDAI IONIQ 5 2022-2024
HYUNDAI IONIQ 6 2023-2024

 


5 Associated Documents

Defect Notice 573 Report

RCLRPT-24V204-1453.PDF 216.912KB

 


Recall Acknowledgement

RCAK-24V204-6233.pdf 645.463KB

 


Remedy Instructions and TSB

RCRIT-24V204-8922.pdf 1560.824KB

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Remedy Instructions and TSB

RCRIT-24V204-0617.pdf 1792.263KB

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Chronology Report

RMISC-24V204-0136.pdf 140.068KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V204&docType=RCL

 


 

Hyundai Reprogramming

J2534 Diagnostic & Reprogramming - Hyundai

 

J2534 Reprogramming Software:

The Hyundai Motor America (HMA) J2534 reprogramming software allows for a common method of communication between aPC and a vehicle electronic control unit (ECU). U.S. EPA and CARB regulations mandate that all 2004 and later vehicle powertrain ECUs support emission-related reprogramming.

 

Vehicle Communication Interfaces (VCI)

The Hyundai J2534 Reprogramming and Diagnostic Tool software supports a SAE J2534-1/2 compliant passthru VCI device for use on Hyundai vehicles sold in the US. The devices, firmware, and application programming interfaces listed below have been tested by HMA and under no circumstances do we recommend the use of a non-approved J2534 device. HMA has worked closely with the following J2534 device manufacturers to ensure the hardware and software comply with all J2534-1/2 specifications.

 

CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
CarDAQ-Plus
CarDAQ-M
SuperGoose-Plus J2534 OEM Vehicle Interface
Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles
RAP2 OEM J2534 Remote Reprogramming Tool
BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI
Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909
GODIAG J2534

 

https://www.hyundaitechinfo.com/external/j2534_diagnostics_and_programming.aspx

 

www.hyundaitechinfo.com

 


 

Bestseller No. 1
CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
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SaleBestseller No. 2
VNCI J2534 for Nano Diagnostic Tools,Support J2534 for Automatic Switch Mode Fast Communication
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Autel MaxiFlash Elite VCI J2534 Pass-Thru ECU Programming Tool, Multi-Protocol PassThru Interface, Work with Autel MaxiSYS Elite II, Elite, MS908, MS908S Pro, MS908CV, MK908P, MK908 Pro II and PC
  • 🌐【Works with Autel MK908, MS908(S/Pro), MK908P, MaxiSys Elite】Autel J2534 work with these tools to program ECUs on specific BMW/ BENZ for specific functions. ★★NOTE: J2534 CANNOT directly work with these single devices. After you received the J2534, you HAVE TO send us both the S/N(12 digits) of your scanner MS908S(etc.) and J2534. So, technically, Autel engineers can help you bind J2534 with your devices. If need any supports, contact us via: 🚘auteldirect @ outlook. com🚘.
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Bestseller No. 4
LAUNCH X431 PRO5 Elite,J2534 Reprogramming Tool, Topology Mapping OBD2 Scanner Diagnostic Tool, CAN/CAFD/DoIP/HD/FCA SGW,Bidirectional Scan Tool, ECU Coding, 50+ Reset, All Systems Scanner
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Bestseller No. 5
Mongoose-Plus J2534 OEM Vehicle Interface Cable - GM OEM Reprogramming and Diagnostics
  • Industry-leading J2534 Pass-Thru Technology: Enabling diagnostics, reprogramming and security functions for dealerships and the independent repair facility. Economical and compact pass-thru devices provides an easy-to-use interface that allows you to repair complex vehicles with OE applications in your shop. Each type (see single branded types above) Mongoose-Plus is engineered to work with one of the following OEM's J2534 applications for Chrysler, Ford, GM, Nissan, Toyota, Subaru, & VW/Audi.
  • Supports Current GM Vehicles: Now includes CAN-FD, DoIP (Diagnostics over Internet Protocol - as defined in J2534-2) and support for J2534 version 5.0. This is the tool that GM dealerships use for diagnostics and reprogramming.
  • NEW Bluetooth Wireless Options Available: Providing wireless connectivity between your laptop and the Mongoose-Plus
  • Expert Product Support: Staffed by technicians who understand vehicle repair and J2534 Pass‑Thru applications to help you with any technical setup questions
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Bestseller No. 6
Autel MaxiFlash Elite VCI J2534 Pass-Thru ECU Programming Tool, Vehicle Communication Interface,Work with Autel MaxiSYS Elite II, Elite, MS908, MS908S Pro, MK908 Pro II, MS908CV, MK908P and PC
  • 【As a multi-protocol Pass-Thru vehicle interface】MaxiFlash Elite is a fully compliant SAE J2534-1 & SAE J2534-2 (March 2006) device. Specially designed to provide users with convenient PC communication and ECU reprogramming capabilities on any modern vehicle diagnostic bus, MaxiFlash Elite offers the most significant features desired by OEM customers: reliability, fast performance and flexibility.
  • 【MaxiFlash Elite is an accessory tool for MK908P, MS908S Pro】Autel MaxiSys Elite to program ECUs on specific for BMW and for Benz vehicles, in case you lost the J-2534 programmer. ★★NOTE: J2534 CANNOT directly work with these single devices. After you received the J2534, you HAVE TO send us both the S/N(12 digits) of your tablet MS908S(etc.) and J2534. So, technically, Autel engineers can help you bind J2534 with your devices. The functions are NOT universally compatible. Please send VIN number to 🚘jmxd2022@outlook.com📧🚘 to check compatibility before your order. If need any supports, Please contact us.
  • 【Wireless with advanced networking functions】Built-In Wireless with advanced networking functions and data storage. Fast performance ensures reprogramming even the newest controllers & Internet upgradable and updatable. Autel MaxiFlash Elite is compatiable with MaxiSYS MS908S, MaxiSYS MS908S Pro , MaxiSYS MS908CV, MaxiCOM MK908, MaxiCOM MK908 Pro, MaxiSYS Elite, MaxiSYS Elite II and Personal Computer
  • 【SAE J2534-1 & J2534-2 Standards】Autel MaxiFlash Elite J2534 is a fully compliant SAE J2534-1 & SAE J2534-2 (March 2006) device, which performs standard PassThru J2534 functionality: Compatible with for Toyota Techstream, Volvo VIDA, Honda HDS, Jaguar-Land Rover IDS and BMW 3G for OEM diagnostics. Autel MaxiFlash J2534 is also specially designed to provide users with P-C communication and ECU reprogramming capabilities on any modern vehicle diagnostic bus, reliability and flexibility.
  • 【Supports simultaneous communication Definition in J2534-1】Autel MaxiFlash Elite Reprogramming Device J2534 supports simultaneous communication definition in J2534-1, running 3 protocols at the same time, which greatly improves reprogramming and diagnostic speed. Embedded with the ARM9 Dual-core processor (clocked up to 500MHz), which further boosts the communicating speed.Rugged aluminum case with non-slip rubber end caps, capable of withstanding harsh environment.

Last update on 2024-03-18 / Affiliate links / Images from Amazon Product Advertising API

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