2016-2017 Hyundai Sonata PHEV Battery BMS and Wiring Replacement (RECALL CAMPAIGN 175)

March 12, 2018 NHTSA CAMPAIGN NUMBER: 18V166000

Voltage Protection Device Improper Activation

If the VPD activates while the vehicle is being operated in Electric Vehicle (EV) mode, there may be a loss of power, increasing the risk of a crash.

 

NHTSA Campaign Number: 18V166

Manufacturer HyundaieBay logo Motor America

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 2,840

 

Summary

HyundaieBay logo Motor America (HyundaieBay logo) is recalling certain 2016-2018 HyundaieBay logo Sonata Plug-In Hybrid vehicles. These vehicles are equipped with a Voltage Protection Device (VPD), designed to protect the high voltage battery module, that may activate inadvertently.

 

Remedy

HyundaieBay logo will notify owners, and dealers will remove the VPD switch and install a new Battery Management System (BMS) that contains an Overvoltage Protection Device (OPD). The recall is expected to begin May 2018. Owners may contact HyundaieBay logo customer service at 1-855-371-9460. HyundaieBay logo’s number for this recall is 175.

 

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.safercar.gov.

 

Check if your Hyundai has a Recall

 


Recall 175 Dealer Best Practice

Date: March 22, 2018

 

Attn: Dealer Principal/General Manager/Service Manager/Parts Manager

Subject: Recall 175: 2016-2018 Sonata Plug-In Hybrid Voltage Protection Device (Remedy Not Yet Available)

 

***IMPORTANT Dealer Stock and Retail Vehicles***

As required by federal law, dealers must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers should also perform all open recalls on used vehicles, demo and rental vehicles prior to placing them into customer use and whenever an affected vehicle is in the shop for any maintenance or repair.

 

Affected Vehicles

HyundaieBay logo has announced, but not yet launched, a safety recall in the United States to replace the Voltage Protection Device (“VPD”) in certain:

  • 2016-2018 HyundaieBay logo Sonata Plug-in Hybrid vehicles produced from July 31, 2015 through August 31, 2017 by HyundaieBay logo Motor Company (“HMC”) in South Korea.

 

Description

The subject vehicles are equipped with a Voltage Protection Device (“VPD”) designed to monitor the hybrid battery’s state of charge and safeguard the hybrid battery from overvoltage by disconnecting the power to the electric motor.  In limited instances, during the charging/discharging process, the hybrid battery could swell and inadvertently activate the VPD switch.  If the VPD switch is activated while the vehicle is driven in the Electric Vehicle (“EV”) drive mode, the electric motor could become inoperative and the vehicle could lose motive power.

 

Service Action

  • We are currently making preparations to implement the recall remedy. A Technical Service Bulletin (TSB) will be provided when the remedy is available.
  • For any customers that are currently experiencing a concern related to this recall, please confirm with HyundaieBay logo Techline that there are no revised instructions.
  • Refer to the below Customer FAQ section.

 

Parts

  • Additional details will be provided when the recall remedy is available.

 

Customer Notification

This recall has been posted to the NHTSA website, and you may receive phone calls from customers with questions regarding this matter.  HyundaieBay logo will notify all owners of the vehicles described above to return their vehicles to their HyundaieBay logo dealers for repair once the remedy is available. Customer notification letters of the recall are scheduled to be mailed in early May, 2018.

Thank you for your prompt attention to this important safety matter and continued commitment to taking care of HyundaieBay logo customers.

 

HyundaieBay logo Motor America


Customer FAQ

Q1:What is the issue?
A1:The subject vehicles are equipped with a Voltage Protection Device (“VPD”) designed to monitor the hybrid battery’s state of charge and safeguard the hybrid battery from overvoltage by disconnecting the power to the electric motor.  In limited instances, during the charging/discharging process, the hybrid battery could swell and inadvertently activate the VPD switch.
Q2:What is the safety concern?
A2:If the VPD switch is activated while the vehicle is driven in the Electric Vehicle (“EV”) drive mode, the electric motor could become inoperative and the vehicle could lose motive power increasing the risk of a crash.
Q3:What are the affected vehicles?
A3:Approximately 2,840 model year 2016 – 2018 HyundaieBay logo Sonata Plug-in Hybrid vehicles produced between 07/31/2015 and 08/31/2017 by HyundaieBay logo Motor Company in South Korea.
Q4:Have there been any accidents or injuries?
A4:HyundaieBay logo is not aware of any accidents or injuries related to this condition.
Q5:What will be done during the recall service?
A5:HyundaieBay logo plans to remove the current VPD switch and install a new Battery Management System (“BMS”) module containing an Overvoltage Protection Device (“OPD”) switch.  HyundaieBay logo is currently making preparations to implement the recall remedy.
Q6:Should customers have their vehicles inspected at their dealer to make sure they are safe?
A6:If a customer owns an affected vehicle, they will receive written notification of the recall by first class mail. In the interim, if the customer experiences a “Check Hybrid System” warning light, they should seek service at their HyundaieBay logo dealer as soon as possible.
Q7:When will owners be notified?
A7:HyundaieBay logo will begin notifying owners of the affected vehicles no later than May, 2018.  In the meantime, updated information about this recall can be found at www.hyundaiusa.com/campaign175 .
Q8:Can the recall service be performed now? (prior to receiving notice)
A8:No. HyundaieBay logo is currently making preparations to implement the recall remedy. Once a remedy becomes available, HyundaieBay logo will notify customers of the affected units.

 


Key Contact Information
Dealer SupportContact InformationDescription
Parts[email protected] 1-800-545-4515Parts ordering hotline
Techline1‐800‐325‐6604Vehicle Technical Support for HyundaieBay logo Dealer Technicians
Warranty HELPREP Line1‐877‐446‐2922Warranty Claim questions for HyundaieBay logo Dealers
Warranty Prior Approval (PA) Center1‐844-371-3808Warranty Prior Approval (PA) Center for HyundaieBay logo Dealers
Xtime Technical Support[email protected] 1‐866‐984‐6355Assistance with Car Care Scheduling:

• Appointment / Shop Capacity Management /

Campaign Integration / Operation Codes

Customer SupportContact InformationDescription
HyundaieBay logo Customer Care Center (Recall / Campaign Questions) 18556713059 Customer questions or concerns related to recall or service campaigns
HyundaieBay logo Recall / Campaign Websitewww.hyundaiusa.com/campaign175    Updated information related to the specific recall or service campaign
HyundaieBay logo Customer Care Center (General Questions)1‐800‐633‐5151Customers general questions, noncampaign related
HyundaieBay logo Roadside Assistance1-800-243-7766HyundaieBay logo Roadside Assistance

 

Key Reference Information
NameSource
Campaign Central Consolidated repository of recall and service campaign dealer best practices.  Located on the service tab homepage in www.HyundaiDealer.com
Car Care Scheduling (Xtime) – Tutorialswww.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling
Car Care Scheduling (Xtime) – Recall Appointment Notification1.     Log into Xtime

2.     Under the menu at the top left, select ‘CONFIGURE’

3.     Under the dealership tab, click “EMAIL COMMUNICATION”

4.     Slide the toggle to “ADVANCED”

5.     Populate as many e-mails as desired in the “PARTS DESK EMAIL FIELD”

Parts Campaign Parts Management (CPM) ProcedureAs applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management
Service Rental Car (SRC) Programwww.HyundaiDealer.com > Service tab
Technical Service Bulletin (TSB)www.HyundaiDealer.com > Service tab > HyundaieBay logo Tech Info
Uncompleted Campaign VIN ListingA listing of vehicles is located on WEBDCS> SERVICE tab> select

UNCOMPLETED CAMPAIGN VIN LISTING

– Dealer Stock (New, SRC, CPO, etc.) and Retailed.

Recall Campaign Websitewww.hyundaiusa.com/recall www.hyundaiusa.com/campaign175
NHTSA Websitewww.safercar.gov

 


 

Technical Service Bulletin

GROUP
RECALL
NUMBER
18-01-019
DATE
MAY, 2018
MODEL
SONATA PLUG-IN
HYBRID (LF PHEV)
SUBJECT:
2016-2017 SONATA PHEV BATTERY BMS AND WIRING REPLACEMENT (RECALL CAMPAIGN 175)

 

 

IMPORTANT

*** Dealer Stock & Retail Vehicles ***

Dealers must perform this Recall Campaign on all affected vehicles prior to customer retail  delivery and whenever an affected vehicle is in the shop for any maintenance or repair. 

When a vehicle arrives at the Service Department, access HyundaieBay logo Motor America’s “Warranty  Vehicle Information” screen via WEBDCS to identify open Campaigns.

 

Description:   

The subject vehicles are equipped with a Voltage Protection Device (“VPD”) designed to monitor the hybrid battery’s state of charge and safeguard the hybrid battery from overvoltage by disconnecting the power to the electric motor.  In limited instances, during the charging/discharging process, the hybrid battery could swell and inadvertently activate the VPD switch.  If the VPD switch is activated while the vehicle is driven in the Electric Vehicle (“EV”) drive mode, the electric motor could become inoperative and the vehicle could lose motive power.

 

The vehicle may display a Check Hybrid System Light On with the following DTC in the Battery Management System (BMS):

  • DTC P1BA7 – Overcharge Detection Active

 

This bulletin’s Service Procedure will convert the PHEV battery overcharge detection system from a Voltage Protection Device (VPD) mechanical type switch to an Overvoltage Protection Device (OPD) electronic type device internal to both the new SUB BMS and MAIN BMS.

 

The following will be performed to achieve the conversion to an OPD type system:

  • Replace the Sub and Main BMS.
  • Replace Sub and Main BMS Wiring.
Applicable Vehicles: Certain 2016-2017MY Sonata Plug-In Hybrid (LF PHEV) vehicles produced between Jun 24, 2015 to Aug 31, 2017.

 

 

Warranty Information: 

Model Op Code OperationOp Time Causal Part Nature  Code Cause Code
Sonata Plug-In Hybrid (LF PHEV)81C016R0BMS & WIRING REPLACEMENT2.0 M/H37503-

E6AS1

I3AZZ3

 

Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair NOTE 1: Submit Claim on Campaign Claim Entry Screen

NOTE 2: If a part is found in need of replacement while performing Recall 175 and the affected part is still under warranty, submit a separate claim using the same repair order. If the affected part is out of warranty, submit a Prior Approval Request for goodwill consideration prior to performing the work.

 

Parts Information:

PART NAMEFIGURE / PART NUMBERREMARK
MAIN BMS1 per vehicle
37513-E6520QQH
SUB BMS1 per vehicle
37513-E6620QQH
MAIN BMS WIRING1 per vehicle
37517-E6520QQH
SUB BMS WIRING1 per vehicle
37517-E6620QQH

 

 

Required Tools List:

  • Insulated safety gloves
  • Cordless impact gun 3/8”
  • Cordless screw gun
  • Ratchet – 3/8” with extensions and 10, 12, and 17 mm sockets
  • Torque wrench
  • Trim tool remover
  • Electrical tape
  • Pocket flat head

 

Service Procedure

  1. Per HEV “General Safety Information and Caution” in the Shop Manual, wear insulated safety gloves for this entire service procedure.

 

  • Open the trunk and access the safety plug under the luggage compartment floor. Unfasten the hook (a) and remove the safety plug (b) by pulling the lever (c) in the direction of the arrow.
  • Record the customer radio presets.
  • Remove the negative terminal from the 12V battery.

 

Tightening torque:
4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)

 

WARNING 

  • Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system.  
  • Wait 5 minutes after disconnection to allow for high voltage system capacitor discharge.     
  • Failure to follow the safety guidelines may result in serious electrical injuries.

 

NOTICE 

The safety plug disconnects both the PHEV Main and Sub High Voltage Battery.

  1. Remove the following to access the PHEV Main and Sub High Voltage Battery:

 

  • Rear Seat Lower Assembly.
  • Rear Seat Back Assembly.
  • Trunk Partition Board.
  • Trunk Cover Board and Felt.
  • Trunk Felt Side Trims on both sides.

 

Refer to the Service Manual for detailed removal instructions.

 

This diagram identifies both the Main and Sub High Voltage Battery Packs in the PHEV.

 

  1. Disconnect the BMS and high voltage connectors (A) from the Sub High Voltage Battery.

 

  1. Remove the mounting nuts and cooling duct (B) from the Sub High Voltage Battery.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.

Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Remove the mounting bolts and Sub High Voltage Battery Pack from the vehicle.

 

Tool: 17mm 3/8” socket + cordless 3/8” impact gun.

Tightening torque:  

78.4 ~ 117.7N.m (8.0 ~ 12.0 kgf.m,57.9 ~ 86.8lb-ft)

 

  1. Remove the mounting bolts and cover from the Sub High Voltage Battery Pack.
  2. Disconnect the BMS connectors and remove the Sub-BMS.

 

NOTICE

The old Sub-BMS ECU will be discarded and replaced later by the new SUB BMS P/N 37513-E6620QQH.

 

  1. Loosen the ground bolt socket and mounting clips.

Pull out the wiring as shown in the picture to the right.

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Place the Sub High Voltage Battery Pack upside down.

Remove the mounting bolts and the watertight case (C).

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Remove the VPD mounting bolts and discard (NOTE:  VPD will be discarded with the wiring).

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.

 

  1. Remove the wiring mounting clips and disconnect the connector.

 

Tool: Trim tool remover and pocket flat head.

 

  1. Remove the mounting clips and remove the VPD mounting bolts.

 

  1. Remove and discard the existing Sub-BMS Wiring including VPD and its 2 mounting bolts.

 

 

 

  1. Install the new SUB BMS WIRING 37517-E6620QQH.

 

NOTICE

The new SUB BMS WIRING does not   have a VPD, it is no longer needed.

 

  1. Reinstall the watertight cover to the Sub High Voltage Battery Pack.

Turn the battery pack back over on the cover side.

 

  1. Install the new SUB BMS 37513-E6620QQH.

 

NOTICE

Make sure to fully connect all BMS connectors until a clicking sound is heard.

 

  1. Reinstall the removed parts on the Sub High Voltage Battery Pack in reverse order of removal.

 

NOTE:  The Main High Voltage Battery Pack will not be removed from the vehicle.

 

  1. Loosen the mounting bolts and remove the front cover (D) of the Main High Voltage Battery Pack.

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.

Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Disconnect the BMS connector
  2. Loosen the mounting bolts and remove the rear cover (E) of the Main High Voltage Battery Pack.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Loosen the mounting bolts, nuts, and remove the cover (F) of the Main High Voltage Battery Pack.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Ratchet 3/8”.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Disconnect the OBC and CPU connectors.

Loosen the ground bolt.

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Remove the inverter power positive and negative cable terminals.

 

WARNING

DO NOT allow the positive and negative cable terminals to contact each other. Tape each terminal temporarily with electrical tape to help prevent contact between the terminals.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Ratchet 3/8”.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Disconnect the fan connector.
  2. Remove the cooling duct mounting bolts and nuts.

 

Remove the harness retainers to the cooling fan.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

  1. Remove the mounting screws and cooling duct (G).

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Disconnect the cooling fan connectors and mounting nuts to remove both cooling fans (H & I).

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

  1. Disconnect the BMS connectors (J).
  2. Remove the mounting nuts and the Main BMS (K).

 

NOTICE

The old Main BMS will be discarded and  replaced later by the new MAIN BMS P/N 37513-E6520QQH.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Disconnect the Power Relay Assy. (PRA) connectors.

 

  1. Remove the mounting bolts and remove the PRA (L).

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

View after PRA removed.

 

  1. Remove the wiring mounting clips and ground bolt.

 

Disconnect the connector.

 

Tool: 10mm 3/8” socket + cordless 3/8” impact gun.
Trim tool remover and pocket flat head.
Tightening torque:
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

 

  1. Remove the main wiring harness mounting clips.

 

Tool:  Trim tool remover and pocket flat head.

 

  1. Remove the mounting clips, VPD nuts, and ground bolt.

 

  1. Remove and discard the existing Main BMS Wiring, the VPD and its 2 mounting nuts.

 

NOTICE

The new MAIN BMS WIRING does not have a VPD. It’s no longer needed.

 

  1. Install the new MAIN BMS WIRING 37517-E6520QQH.

 

  1. Reinstall the PRA.

 

  1. Install the new MAIN BMS 37513-E6520QQH.

 

NOTICE

Make sure to fully connect all BMS connectors until a clicking sound is heard.

 

  1. Reinstall all the remaining parts in the reverse order of removal.
  2. Perform a brief test drive for at least 10 minutes to ensure the vehicle is operating normally. If possible, confirm the vehicle can take a charge by looking for the green charging light on the top center of the dash.
  3. Perform a Fault Code Search of All Systems by GDS to make sure there are no stored DTC.
  4. Restore the recorded customer radio presets and set the time.

 


3 Affected Products

Vehicle

HYUNDAIeBay logoSONATA PLUG-IN HYBRID2016-2018

 


10 Associated Documents

Manufacturer Notices(to Dealers,etc)- March 22, 2018 – Subject: Recall 175: 2016-2018 Sonata Plug-In Hybrid Voltage Protection Device (Remedy Not Yet Available)

RCMN-18V166-6465.pdf 113.068KB

 


Defect Notice 573 Report

RCLRPT-18V166-9048.PDF 214.76KB

 


Chronology

RMISC-18V166-5511.pdf 75.454KB

 


Recall Acknowledgement

RCAK-18V166-6826.pdf 245.799KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-18V166-5660.pdf 1258.388KB

 


Recall Quarterly Report #1, 2018-2

RCLQRT-18V166-8579.PDF 214.526KB

 


Recall Quarterly Report #2, 2018-3

RCLQRT-18V166-0735.PDF 211.245KB

 


Recall Quarterly Report #3, 2018-4

RCLQRT-18V166-9021.PDF 211.339KB

 


Safety Bulletin – SUBJECT: 2016-2017 SONATA PHEV BATTERY BMS AND WIRING REPLACEMENT (RECALL CAMPAIGN 175)

RCSB-18V166-6675.pdf 1286.665KB

 


Recall Quarterly Report #4, 2019-1

RCLQRT-18V166-8088.PDF 211.448KB

 


Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=18V166&docType=RCL

 

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  • Indication Displays - LED display that can tell you the status as well as indicate errors while charging your electric vehicle.
SaleBestseller No. 5
Autel Level 2 EV Charger 40 Amp Home Smart AI Electric Vehicle (EV) Charger, Wi-Fi and Bluetooth Enabled EVSE, with in-Body Holster and 25-Foot Cable NEMA 14-50 Plug(Dark Gray)
  • 【Trusted Level 2 EV Charger from a Leading EV Charger Brand】Autel has been building advanced automotive diagnostic and energy solutions since 2004. This MaxiCharger AC Home Level 2 EV Charger was engineered over two years to deliver one of the safest, smartest, and best-designed EV chargers for home use. A reliable electric vehicle charger built for long-term performance.
  • 【Quick 5-Minute Setup – Plug-in Home EV Charger with NEMA 14-50】Install this home EV charger indoors or outdoors in just 5 minutes by plugging it into a standard NEMA 14-50 outlet. Save thousands on installation costs. The plug-in EVSE design makes mounting, removing, or taking your EV charger with you when moving extremely convenient.
  • 【Smart App Control for Your Home EV Charger (16A–40A Adjustable)】With the Autel Charge App, you can manage your EV charger remotely: adjust charging power from 16A–40A, set smart schedules, and lower costs using off-peak charging. RFID start/stop access adds security to your Level 2 EV charger, preventing unauthorized charging.
  • 【NEMA 4X Weatherproof Electric Vehicle Charger Built for Any Environment】This EV charger is NEMA 4X-rated for superior durability—dust-tight, water-tight, and resistant to snow, rain, and ice. Whether used indoors, in the garage, or outdoors, this home Level 2 EV charger is built to withstand harsh environments and deliver stable charging performance year-round.
  • 【 Long-Term Support for Your Home EV Charger – 3-Year Warranty】Autel provides a 3-year warranty, automatic OTA app updates, and 24/7 customer support to ensure your EV charger always operates at peak performance. Our dedicated service team guarantees a seamless and worry-free electric vehicle charging experience.

Last update on 2026-05-27 / Affiliate links / Images from Amazon Product Advertising API


 

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