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 Hyundai Motor America
Components HYBRID PROPULSION SYSTEM
Potential Number of Units Affected 2,840
Summary
Hyundai Motor America (Hyundai) is recalling certain 2016-2018 Hyundai 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
Hyundai 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 Hyundai customer service at 1-855-371-9460. Hyundai’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
Hyundai has announced, but not yet launched, a safety recall in the United States to replace the Voltage Protection Device (“VPD”) in certain:
- 2016-2018 Hyundai Sonata Plug-in Hybrid vehicles produced from July 31, 2015 through August 31, 2017 by Hyundai 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 Hyundai 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. Hyundai will notify all owners of the vehicles described above to return their vehicles to their Hyundai 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 Hyundai customers.
Hyundai 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 Hyundai Sonata Plug-in Hybrid vehicles produced between 07/31/2015 and 08/31/2017 by Hyundai Motor Company in South Korea. |
| Q4: | Have there been any accidents or injuries? |
| A4: | Hyundai is not aware of any accidents or injuries related to this condition. |
| Q5: | What will be done during the recall service? |
| A5: | Hyundai plans to remove the current VPD switch and install a new Battery Management System (“BMS”) module containing an Overvoltage Protection Device (“OPD”) switch. Hyundai 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 Hyundai dealer as soon as possible. |
| Q7: | When will owners be notified? |
| A7: | Hyundai 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. Hyundai is currently making preparations to implement the recall remedy. Once a remedy becomes available, Hyundai will notify customers of the affected units. |
| Key Contact Information | ||
| Dealer Support | Contact Information | Description |
| Parts | [email protected] 1-800-545-4515 | Parts ordering hotline |
| Techline | 1‐800‐325‐6604 | Vehicle Technical Support for Hyundai Dealer Technicians |
| Warranty HELPREP Line | 1‐877‐446‐2922 | Warranty Claim questions for Hyundai Dealers |
| Warranty Prior Approval (PA) Center | 1‐844-371-3808 | Warranty Prior Approval (PA) Center for Hyundai Dealers |
| Xtime Technical Support | [email protected] 1‐866‐984‐6355 | Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes |
| Customer Support | Contact Information | Description |
| Hyundai Customer Care Center (Recall / Campaign Questions) | 1‐855‐671‐3059 | Customer questions or concerns related to recall or service campaigns |
| Hyundai Recall / Campaign Website | www.hyundaiusa.com/campaign175 | Updated information related to the specific recall or service campaign |
| Hyundai Customer Care Center (General Questions) | 1‐800‐633‐5151 | Customers general questions, non‐campaign related |
| Hyundai Roadside Assistance | 1-800-243-7766 | Hyundai Roadside Assistance |
| Key Reference Information | |
| Name | Source |
| 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) – Tutorials | www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling |
| Car Care Scheduling (Xtime) – Recall Appointment Notification | 1. 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) Procedure | As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management |
| Service Rental Car (SRC) Program | www.HyundaiDealer.com > Service tab |
| Technical Service Bulletin (TSB) | www.HyundaiDealer.com > Service tab > Hyundai Tech Info |
| Uncompleted Campaign VIN Listing | A listing of vehicles is located on WEBDCS> SERVICE tab> select
UNCOMPLETED CAMPAIGN VIN LISTING – Dealer Stock (New, SRC, CPO, etc.) and Retailed. |
| Recall Campaign Website | www.hyundaiusa.com/recall www.hyundaiusa.com/campaign175 |
| NHTSA Website | www.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 Hyundai 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 | Operation | Op Time | Causal Part | Nature Code | Cause Code |
|---|---|---|---|---|---|---|
| Sonata Plug-In Hybrid (LF PHEV) | 81C016R0 | BMS & WIRING REPLACEMENT | 2.0 M/H | 37503-
E6AS1 | I3A | ZZ3 |
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 NAME | FIGURE / PART NUMBER | REMARK |
|---|---|---|
| MAIN BMS | 1 per vehicle | |
| 37513-E6520QQH | ||
| SUB BMS | 1 per vehicle | |
| 37513-E6620QQH | ||
| MAIN BMS WIRING | 1 per vehicle | |
| 37517-E6520QQH | ||
| SUB BMS WIRING | 1 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:
- 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.
- 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.
- Disconnect the BMS and high voltage connectors (A) from the Sub High Voltage Battery.
- 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)
- 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)
- Remove the mounting bolts and cover from the Sub High Voltage Battery Pack.
- 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.
- 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)
- 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)
- 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.
- Remove the wiring mounting clips and disconnect the connector.
Tool: Trim tool remover and pocket flat head.
- Remove the mounting clips and remove the VPD mounting bolts.
- Remove and discard the existing Sub-BMS Wiring including VPD and its 2 mounting bolts.
- Install the new SUB BMS WIRING 37517-E6620QQH.
NOTICE
The new SUB BMS WIRING does not have a VPD, it is no longer needed.
- Reinstall the watertight cover to the Sub High Voltage Battery Pack.
Turn the battery pack back over on the cover side.
- Install the new SUB BMS 37513-E6620QQH.
NOTICE
Make sure to fully connect all BMS connectors until a clicking sound is heard.
- 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.
- 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)
- Disconnect the BMS connector
- 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)
- 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)
- 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)
- 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)
- Disconnect the fan connector.
- 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)
- 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)
- 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)
- Disconnect the BMS connectors (J).
- 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)
- Disconnect the Power Relay Assy. (PRA) connectors.
- 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.
- 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)
- Remove the main wiring harness mounting clips.
Tool: Trim tool remover and pocket flat head.
- Remove the mounting clips, VPD nuts, and ground bolt.
- 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.
- Install the new MAIN BMS WIRING 37517-E6520QQH.
- Reinstall the PRA.
- Install the new MAIN BMS 37513-E6520QQH.
NOTICE
Make sure to fully connect all BMS connectors until a clicking sound is heard.
- Reinstall all the remaining parts in the reverse order of removal.
- 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.
- Perform a Fault Code Search of All Systems by GDS to make sure there are no stored DTC.
- Restore the recorded customer radio presets and set the time.
3 Affected Products
Vehicle
| HYUNDAI | SONATA PLUG-IN HYBRID | 2016-2018 |
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
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