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 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
Remedy Instructions and TSB
RCRIT-24V204-0617.pdf 1792.263KB
Chronology Report
RMISC-24V204-0136.pdf 140.068KB
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.
https://www.hyundaitechinfo.com/external/j2534_diagnostics_and_programming.aspx
www.hyundaitechinfo.com
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-204
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Hyundai Motor America MAR 15, 2024 NHTSA Recall No. : 24V-204 Manufacturer Recall No. : 257/021G Manufacturer Information :
Manufacturer Name : Hyundai Motor America Address : 10550 Talbert Avenue
Fountain Valley CA 92708
Company phone : 800-633-5151
Population :
Number of potentially involved : 98,878 Estimated percentage with defect : 1 %
Vehicle Information :
Vehicle 1 : 2022-2024 Hyundai IONIQ 5 Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : HYBRID ELECTRIC
Descriptive Information : The subject vehicles include 69,316 model year 2022-2024 Hyundai IONIQ 5 vehicles produced on the specified dates by Hyundai Motor Company (“HMC”) for sale in the
U.S. market, including 27 vehicles used in Robotaxi fleets. Production Dates : OCT 04, 2021 – FEB 19, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2023-2024 Hyundai IONIQ 6 Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : The subject vehicles include 18,017 model year 2023-2024 Hyundai IONIQ 6 vehicles produced on the specified dates by HMC for sale in the U.S. market. Production Dates : DEC 14, 2022 – DEC 25, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2023-2024 Genesis GV60 Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : HYBRID ELECTRIC
Descriptive Information : The subject vehicles include 6,709 model year 2023-2024 Genesis GV60 vehicles produced on the specified dates by HMC for sale in the U.S. market. Production Dates : FEB 04, 2022 – FEB 02, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-204 Page 2 Vehicle 4 : 2023-2024 Genesis GV70 “Electrified” Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : HYBRID ELECTRIC
Descriptive Information : The subject vehicles include 3,083 model year 2023-2024 Genesis GV70 electric vehicles produced on the specified dates by HMC for sale in the U.S. market. Production Dates : JAN 25, 2023 – MAR 12, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2023-2024 Genesis G80 “Electrified” Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC
Descriptive Information : The subject vehicles include 753 model year 2023-2024 Genesis G80 electric vehicles produced on the specified dates by HMC for sale in the U.S. market. Production Dates : FEB 23, 2022 – JAN 15, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The subject vehicles are equipped with an Integrated Charging Control Unit (“ICCU”) which charges the vehicle’s 12-volt auxiliary battery and powers low voltage vehicle accessory equipment. The ICCU may be subject to certain electrical load conditions that can damage internal components and open the ICCU fuse. An open ICCU fuse results in an inability to charge the 12-volt auxiliary battery. Upon fault detection, and accompanied by a series of driver warnings, the vehicle will enter a design-intended “fail-safe” driving mode that allows immediate full propulsion while gradually reducing motive power over an extended time period. Vehicle systems such as air bags, braking, and powered steering remain operational.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the vehicle continues to be driven an extended distance in “fail-safe” mode with the MIL illuminated and warning message(s) in the instrument cluster, the vehicle could eventually lose all motive power, potentially increasing the risk of a crash.
Description of the Cause : The ICCU internal componentry can become damaged due to various conditions such as overcurrent, overvoltage induced at the end of high-voltage battery charging, and certain thermal loading during operation or driving.
Identification of Any Warning The following warning symptoms will occur when an ICCU fault is detected and present: The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-204 Page 3 that can Occur : A. Illumination of MIL in vehicle instrument cluster
B. Audible chime
C. Warning messages displayed in vehicle instrument cluster
D. Reduced motive power or inability to accelerate above a certain speed The vehicle retains motive power for approximately 22-45 minutes after the initial ICCU fault detection. The available range is dependent upon 12-volt vehicle accessory load. Involved Components : Component Name 1 : ICCU ASSEMBLY
Component Description : Integrated Charging Control Unit for IONIQ 5 Component Part Number : 36400-1XAA0 Component Name 2 : ICCU ASSEMBLY
Component Description : Integrated Charging Control Unit for IONIQ 6 Component Part Number : 36400-1XEA0 Component Name 3 : ICCU ASSEMBLY
Component Description : Integrated Charging Control Unit for GV60 Component Part Number : 36400-1XCA0 Component Name 4 : ICCU ASSEMBLY
Component Description : Integrated Charging Control Unit for GV70 EV Component Part Number : 36400-1XDA0 Component Name 5 : ICCU ASSEMBLY
Component Description : Integrated Charging Control Unit for G80 EV Component Part Number : 36400-1XBA0 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-204
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Supplier Identification : Component Manufacturer
Name : MOBIS Corporation
Address : 203 Teheran-ro, Gangnam-gu Seoul Foreign States 06141
Country : Korea, Republic of
Chronology :
Please see attached chronology of events leading up to defect decision.
Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicles to a Hyundai dealer or Genesis retailer to have the ICCU software updated. Additionally, the ICCU and associated fuse will be inspected and replaced, if necessary. The remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s or Genesis’ New Vehicle Limited Warranty. Additionally, Hyundai/Genesis will provide owners of affected vehicles reimbursement for out-of-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 22, 2024. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The remedy ICCU software prevents overcurrent and implements voltage peak reduction at the end of EV battery charging. The remedy software also revises the electric water pump operational threshold to reduce thermal loading during charging and driving.
The updated ICCU software was implemented as a production running change from February 29, 2024, through March 5, 2024, according to the specific affected model. Recall Schedule :
Description of Recall Schedule : Dealers will be notified electronically on the specified dates.
Owners will be notified via certified mail on the specified dates.
Planned Dealer Notification Date : MAY 14, 2024 – MAY 14, 2024
Planned Owner Notification Date : MAY 14, 2024 – MAY 14, 2024
* NR – Not Reported
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