Recall 196 – Lithium-Ion Battery May Short Circuit – 2019-2020 Hyundai Kona

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October 13, 2020 NHTSA CAMPAIGN NUMBER: 20V630000

Lithium-Ion Battery May Short Circuit

An electrical short in the Li-ion battery increases the risk of a fire.

 

NHTSA Campaign Number: 20V630

Manufacturer Hyundai Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 6,707

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2019-2020 Kona Electric vehicles. The lithium-ion (Li-ion) battery may short-circuit after it is fully charged.

 

Remedy

Hyundai will notify owners, and dealers will update the Battery Management System (BMS) software and inspect the Li-ion battery, replacing it if necessary, free of charge. Owners are advised to park their vehicles outside and away from structures until the repair is complete. The recall began November 13, 2020. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 196.

 

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

 


Technical Service Bulletin          GROUP

RECALL

NUMBER

21-01-006H

DATE

FEBRUARY, 2021

MODEL(S)

Kona Electric

(OS EV)

SUBJECT:

HIGH VOLTAGE BATTERY SOFTWARE UPDATE, INSPECTION AND REPLACEMENT DTC P1AA600 (RECALL CAMPAIGN 196)

 

This TSB supersedes TSB# 20-01-042H to revise the Service Procedure, add HV battery replacement and update the Warranty section with additional OP codes.

 

IMPORTANT

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 “Vehicle Information Screen (VIS)” screen via WEBDCS to identify open Campaigns.

 

Description: The battery system in certain 2019-2020MY Kona Electric vehicles may be faulty and/or contain software that may need to be updated. These conditions may increase the risk of an electrical short circuit. Follow the procedure to update the specified ECU modules. An inspection is required after the software updates are completed to determine if additional repairs are necessary.

 

Applicable Vehicles:  Certain 2019-2020MY Kona Electric (OS EV)

 

Part Information:

If high voltage (HV) battery replacement is necessary according to the Service Procedure, refer to TSB 20-EE-001H-2 (or latest revision) for replacement procedures, ordering instructions, and approval guidelines.

 

Warranty Information:

Model Op. Code Operation Op. Time Causal Part Nature Cause
Kona Electric  (OS EV) 01D076RA BMS & VCULDC UPDATE 0.5 M/H 37501-K4000QQH I11 ZZ3
01D076RB IGPM, MCU, BMS & VCULDC UPDATE 1.1 M/H 37501-K4000QQH I11 ZZ3
01D076RC  HV BATTERY REPLACEMENT 3.4 M/H 37501-K4000QQH I11 ZZ3
01D076RD HV BATTERY REPLACEMENT & BMS UPDATE 3.7 M/H 37501-K4000QQH I11 ZZ3

 

NOTE 1: Submit Claim on Campaign Claim Entry Screen.

NOTE 2: If a part is found in need of replacement while performing this Recall Campaign and the affected part is still under warranty, submit a separate warranty 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.

 

Service Procedure:

 

  1. Scan for DTCs in the BMS System using the GDS.

 

NOTICE

Ensure all Freeze Frame Data and Information Codes are collected if any DTCs are detected in the BMS System.

 

If DTCs are detected in the BMS System, collect all related Freeze Frame Data and all Information Codes for the DTC.

  • For DTC P1AA600:
    • Replace the high voltage battery according to procedures in TSB 20-EE-001H-2 (or latest revision).
    • When repairs are completed and there are no DTCs, continue to Step 2.
  • For other DTC, follow the related shop manual to repair the vehicle then continue to Step 2.

 

If no DTCs are detected in the BMS System:

Proceed to Step 2.

 

  1. If there are no DTCs in the BMS System, update the ECU software using the GDS for the following systems. Reference the GDS Information section for Event #.

 

NOTICE

Do not proceed with ECM updates before diagnosing and repairing all DTCs in the BMS System.

 

Note: Check Campaign 960 completion status on VIS. If Campaign 960 was completed, a software update for (c) and (d) is not required since these systems were previously updated during Campaign 960.

 

NOTICE

Perform all ECM updates in AUTO mode first. If AUTO mode is not successful then MANUAL mode can be used.

 

a) BMS (Battery Management System)

b) VCULDC (Vehicle Control Unit & Low DC-DC Converter)

c) IGPM (Integrated Gateway Power Module)

d) MCU (Motor Control Unit)

 

Refer to TSB 15-GI-001 for the general GDS Mobile ECU update procedures.

 

! WARNING

THE 12V BATTERY VOLTAGE CHECK IS CRITICAL FOR THIS MULTI-ECU UPDATE AS IT  COULD DRAW DOWN THE 12V BATTERY WHILE THE IGNITION IS ON. 

 

STOCK VEHICLES ARE PRONE TO LOW BATTTERY CONDITION. OPERATE A STOCK VEHICLE AT READY ON FOR 20 MINUTES PRIOR TO STARTING THE MULTI-ECU UPDATE.

 

THIS WILL ENSURE 12V BATTERY WILL BE CHARGED TO AN ADEQUATE LEVEL, PREVENTING POTENTIAL UPDATE FAILURE OR CONTROLLER DAMAGE.

 

! WARNING

If a low battery warning message appears  on the GDS, operate the vehicle in Ready mode for at least 20 minutes to ensure the 12 V battery is adequately charged before performing any software updates.

 

  1. After successful completion of the applicable system updates, search all systems for DTCs.

 

If no DTC are found, the procedure is complete.

 

NOTICE 

Refer to TSB 20-EE-001H-2 for high voltage (HV) battery approval guidelines.

 

DTC, Freeze Frame Data (FFD), current BMS data screens, and other information must be submitted according to the procedures in TSB 20-EE-001H-2 (or latest revision).

 

If DTCs are detected in the BMS System, collect all related Freeze Frame Data and all Information Codes for the DTC.

  • For DTC P1AA600:
    • Replace the high voltage battery according to procedures in TSB 20-EE-001H-2 (or latest revision).
    • When repairs are completed and there are no DTCs, follow Step 2 to update the BMS software, if applicable.
  • For other DTC, follow the related shop manual to repair the vehicle.

 

GDS Information:

NOTICE

All ECM updates should be performed in Auto Mode first. If the ECM update starts but then fails in Auto Mode, perform these updates in Manual Mode.

Event # Description
655*

656*

 

OS EV – IMPROVED MONITORING LOGIC APPLICATION(BMS)

OS EV – IMPROVED MONITORING LOGIC APPLICATION(BMS,ROM duplication)

Note: 1) Select Event #655 first. 2) If an error message is displayed or the update is not successful, try Event #656. 3) Try an event after #655/656 if one is available.

657* OS EV – HIGH VOLTAGE BATTERY MONITORING LOGIC APPLICATION(VCULDC)
590* OS EV – HIGH VOLTAGE BATTERY MONITORING LOGIC APPLICATION(MCU) Note: Not required if Campaign 960 is completed.
592* OS EV – HIGH VOLTAGE BATTERY MONITORING LOGIC APPLICATION(IGPM) Note: Not required if Campaign 960 is completed.

 

(*or later event if one is shown for each system)

 

ROM ID INFORMATION TABLE: 

1) BMS (#655)

The BMS ROM ID can be found on the LH side of the high voltage battery underneath the vehicle. Cross-reference the ROM ID in the column labeled “OLD” in the table to find the applicable BMS P/No. and NEW ROM ID.

VEHICLE SYSTEM BMS P/NO ROM ID
OLD NEW
OSEV BMS 375A0-K4050 5300 6100
5400
5500
5700
5800
5900
6000
6020
6040
6050
6060
6070
6080
6090
OSEV BMS 375A0-K4000 5302 6102
5402
5502
5702
5802
5902
6002
6022
6042
6052
6062
6072
6082
6092
OSEV BMS 375A0-K4450 5304 6104
5404
5504
5704
5804
5904
6004
6024
6044
6054
6064
6074
6084
6094
OSEV BMS 375A0-K4400 5306 6106
5406
5506
5706
5806
5906
6006
6026
6046
6056
6066
6076
6086
6096
OSEV BMS 375A0-K4051 6200 6600
6220
6240
6540
6550
6560
6570
6580
6590
OSEV BMS 375A0-K4001 6202 6602
6222
6242
6542
6552
6562
6572
6582
6592
OSEV BMS 375A0-K4451 6204 6604
6224
6244
6524
6544
6554
6564
6574
6584
6594
OSEV BMS 375A0-K4401 6206 6606
6226
6246
6526
6546
6556
6566
6576
6586
6596
OSEV BMS 375A0-K4052 6400 6800
6500
6700
6730
6740
6770
6780
6790
OSEV BMS 375A0-K4002 6402 6802
6502
6702
6732
6742
6772
6782
6792
OSEV BMS 375A0-K4452 6504 6804
6734
6744
6774
6784
6794
OSEV BMS 375A0-K4402 6506 6806
6736
6746
6776
6786
6796

 

2) BMS (#656)

The BMS ROM ID can be found on the LH side of the high voltage battery underneath the vehicle. Cross-reference the ROM ID in the column labeled “OLD” in the table to find the applicable BMS P/No. and NEW ROM ID

VEHICLE SYSTEM BMS P/NO ROM ID
OLD NEW
OSEV BMS 375A0-K4052 6400 6900
6500
6700
6730
6740
6770
6780
6790
OSEV BMS 375A0-K4002 6402 6902
6502
6702
6732
6742
6772
6782
6792
OSEV BMS 375A0-K4452 6504 6904
6734
6744
6774
6784
6794
OSEV BMS 375A0-K4402 6506 6906
6736
6746
6776
6786
6796

 

2) VCULDC(#657)

VEHICLE SYSTEM VCULDC P/NO. ROM ID
OLD NEW
OS EV VCULDC 36601-0E170 EOSEJNM-NS0-D000

EOSEJNM-NS1-D000

EOSEJNM-NS2-D000

EOSEKNM-NS3-D000

EOSEKNM-NS4-D000

EOSEKNM-NS5-D000

EOSEKNM-NS6-D000

EOSEKNM-NS7-D000

EOSEKNM-NS8-D000

 

3) MCU (#590)

VEHICLE SYSTEM MCU P/NO. ROM ID
OLD NEW
OS EV MCU 36601-0E170 EOSEJDL-MS0-D000

EOSEJDL-MS1-D000

EOSEKNLMS1-D000

EOSEKNLMS2-D000

 

4) IGPM (#592)

VEHICLE SYSTEM IGPM P/NO. ROM ID
OLD NEW
OS EV IGPM 91950-K4010

91950-K4020

91950-K4030

91950-K4040

91950-K4050

91950-K4060

91950-K4070

91950-K4080

91950-K4090

91950-K4100

91950-K4110

91950-K4120

91950-K4130

91950-K4140

91950-K4011

91950-K4021

91950-K4031

91950-K4041

91950-K4051

91950-K4061

91950-K4071

91950-K4081

91950-K4091

91950-K4101

91950-K4111

91950-K4121

91950-K4131

91950-K4141

K401

K402

K403

K404

K405

K406
K601

K602

K603

 

MANUAL MODE PASSWORD INFORMATION TABLE:

#655 (BMS)

MENU P/W
OS EV BMS 375A0-K4050 4051
OS EV BMS 375A0-K4000 4001
OS EV BMS 375A0-K4450 4451
OS EV BMS 375A0-K4400 4401
OS EV BMS 375A0-K4051 4052
OS EV BMS 375A0-K4001 4002
OS EV BMS 375A0-K4451 4452
OS EV BMS 375A0-K4401 4402
OS EV BMS 375A0-K4052 4053
OS EV BMS 375A0-K4002 4003
OS EV BMS 375A0-K4452 4453
OS EV BMS 375A0-K4402 4403

 

#656 (BMS) 

MENU P/W
OS EV BMS 375A0-K4052 0405
OS EV BMS 375A0-K4002 0400
OS EV BMS 375A0-K4452 0445
OS EV BMS 375A0-K4402 0440

 

#657 (VCULDC)

MENU P/W
OS EV VCULDC36601-0E170 0170

 

#590 (MCU)

MENU P/W
OS EV MCU 36601-0E170 0170

 

#592 (IGPM)

MENU P/W
OS EV IGPM 91950-K4010~K140, K4011~K141(ROM ID : K401/2/3/4/5) 3000
OS EV IGPM 91950-K4010~K140, K4011~K141(ROM ID : K601/2) 3001

 


Q&A

Q1: What is the issue?

A1: The high-voltage battery system in the subject vehicles might contain certain electrical deficiencies, such as internal damage to certain cells of the lithium-ion battery and/or faulty battery management system (“BMS”) control software that could increase the risk of an electrical short circuit after fully charging the Li-ion battery. Hyundai is continuing to actively investigate this condition for identification of a specific root cause.

 

Q2: What are the affected vehicles?

A2: The subject vehicles include model year 2019-2020 Hyundai Kona electric vehicles (“EV”) built between August 28, 2018 and March 2, 2020 by Hyundai Motor Company (“HMC”) for sale in the U.S. market. The affected population was determined based on suspect production lot information provided by the supplier and vehicle assembly records.

 

Q3: What is the safety concern?

A3: An electrical short in Li-ion battery could increase the risk of a fire.

 

Q4: Have there been any accidents or injuries?

A4: To date, Hyundai is not aware of any crashes or fires in the U.S. attributable to this condition. Hyundai is aware of at least nine fires in South Korea, two in Canada, and two in the European market.

 

Q5: What will be done during the recall service at the dealer?

A5: Customers are advised to park their vehicles outdoors and/or away from structures until their vehicle is remedied. Hyundai is planning to notify owners to bring their vehicles to the nearest Hyundai dealership for inspection and replacement of the Li-ion battery, if necessary. As an added level of protection, Hyundai is also planning on updating the BMS software to allow for detection of abnormalities in the high-voltage battery system while parked. This current TSB addresses the software update and inspection, including the repair process for those vehicles that have the DTC P1AA600 found during inspection. The remedy procedure will be performed at no charge. Hyundai will provide reimbursement to owners for repairs according to the plan submitted to NHTSA on May 16, 2018.

 

Q6: When will owners be notified?

A6: Owners will be mailed notification letters beginning in mid-December 2020.


 


2 Affected Products

Vehicle

MAKE MODEL YEAR
HYUNDAI KONA ELECTRIC 2019-2020

 


10 Associated Documents

Remedy Instructions and TSB

RCRIT-20V630-6812.pdf 181.82KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V630-6331.pdf 335.821KB

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V630-8845.PDF 211.143KB

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Remedy Instructions and TSB

RCRIT-20V630-8491.pdf 389.72KB

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V630-9565.PDF 211.242KB

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Recall 573 Report – Amendment 1

RCLRPT-20V630-1434.PDF 214.44KB

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Recall Acknowledgement

RCAK-20V630-6127.pdf 244.646KB

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Defect Notice 573 Report

RCLRPT-20V630-7305.PDF 214.468KB

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Recall Quarterly Report #3, 2021-2

RCLQRT-20V630-4522.PDF 211.329KB

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Manufacturer Notices(to Dealers,etc) – Kona EV Battery System

RCMN-20V630-0691.pdf 314.655KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V630&docType=RCL

 


 

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  • Dual-Use Convenience: We've got your charging needs covered, whether you're at home or on the road. You will receive a complimentary storage bag, bracket, charging cable hook, and 4 expansion screws. You can set it up as a permanent personal charging station right in your garage or store it in the provided storage bag when you're on the go, charging wherever there's an available outlet.
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EVIQO Level 2 EV Charger - 48 Amp EV Charger Level 2, 240V Electric Vehicle Charging Stations, EV Level 2 Charger NEMA 14-50/Hardwire EVSE Level 2 Charger, 25' Cord Electric Car Charger Energy Star/UL
  • 9X FASTER: EVIQO is electric vehicle charger for home providing 38 m/h (40 amp ev charger by default) and 46 m/h if hardwired and set as a 48A EV charger. Max output for EV charging station level 2 is set with a dip switch. Adjustable current: 1A increment in EVIQO app. Stay EVIPOWER-ful with live 24/7 post-sale customer support.
  • SAFE, USA CERTIFIED: EVIQO electric car charger level 2 is UL compliant, Energy Star, ETL and FCC certified EV charging station with 3 years Manufacturer Warranty. EVIQO level 2 home ev charger is weatherproof. This EV car charger level 2 is suitable for use as an indoor/ outdoor EV charger. EVIQO EV wall charger level 2 meets NEMA 4 and IP66 protection standards.
  • SMART APP: EVIQO surveyed 1,800 EV owners to create EV home charger level 2 app. Set up to 3 schedules for cost savings during off-peak rates. Get smart tips and reminders, track power/costs live and monitor the charging history. Enjoy sleek intuitive interface of your electric car charger 240v. EVIQO level 2 car charger consistently enhances its firmware with remote OTA updates.
  • COMPATIBLE WITH ALL EVs: EVIPOWER electric car home charging stations are equipped with heavy duty rubberized SAE J1772 connector compatible with all EVs / PHEVs in NA: all Tesla models, Chevrolet Bolt, VW ID 4, Nissan Leaf, Polestar 2, Ford Mustang Mach-E, IONIQ 5/6, BMW i3, i4, iX, Mercedes EQS, Audi, Rav4, Jeep Wrangler 4xe level 2 charger (Tesla requires an adapter).
  • FIRST-IN-CLASS: EVIQO electric vehicle charging stations offer the MARKET'S LONGEST 37" input cable with a NEMA 14-50 plug along with a 25' EXTRA LONG output cable.
Bestseller No. 8
EMPORIA Level 2 EV Charger - NEMA 14-50 EVSE w/ J1772 Charger - 48 amp EV Charger Level 2, 240v WiFi Enabled Electric Vehicle Charging Station, UL/Energy Star, 24ft Electric Car Charger Cable (Black)
  • Award-Winning Charging Performance: Experience top-tier charging with the Emporia Level 2 EV Charger, proudly named the "Best Smart EV Home Charger" by Motortrend and the "Best EV Charger of 2024" from InsideEVs and State of Charge
  • Safety, Certification, and Peace of Mind: UL listed and ENERGY STAR certified, meeting stringent standards (NEC 625, SAE J1772, UL 817, UL 991, UL 2231, UL 2251, and UL 2594). Emporia EV Chargers are protected by a 3 Year Warranty.
  • Versatile Installation Options: Preconfigured for NEMA Type 14-50P compliant with 2017 NEC Section 625.17 for up to 40A or convert to Hardwired for up to 48A. Professional installation recommended for optimal safety and performance.
  • Get the Benefits of Smart Charging: Connect via 2.4 GHz WiFi to access real-time energy data and manage charging from your mobile device. Schedule charging sessions to optimize utility rates and performance.
  • Universal Compatibility: Equipped with a secure SAE J1772 connector, compatible with all EVs in North America, including Tesla, Chevrolet Bolt, VW ID 4, Nissan Leaf, Ford Mustang Mach-E, IONIQ 5/6, BMW i3, i4, iX, Audi, and Jeep Wrangler 4xe.
Bestseller No. 9
Level 1/2 EV Charger, SEGUMA 16Amp Electric Car Charger Portable EV Charger 25FT Cable with NEMA 6-20 Plug and NEMA 5-15 Adapter, Home Mobile EV Charging Station for J1772 BEVs/PHEVs, 16Amp 110V-240V
  • Fast and Efficient Charging---The Seguma level 2 EV charger is equipped with NEMA 6-20 Plug, offers 240V, 16A, 3.84kW output current, approximately 4x faster than 8A level 1 ev chargers, reducing the time required to charge an electric vehicle.
  • Level 1+Level 2 EV Charger--- This portable ev charger is equipped with NEMA 6-20 plug (Level 2 circuits, 240V, 16A) and attached a NEMA 5-15 adapter (Level 1 circuits, 120V, 12A), Whether you have access to a standard household outlet or a dedicated EV charging station, our electric car charger adapts to your charging needs.
  • Universal Compatibility--- Seguma 16A j1772 Charger is engineered with standardized J1772 connector, works flawlessly with any electric vehicle featuring a j1772 charging port. Whether you drive a Ford, Kia, Chevrolet Bolt, or any other EV model, this evse level 2 charger ensures hassle-free charging every time.
  • Intelligent Charging Features---Feature with built-in advanced chipset, Seguma ev charger provides extensive protection against lightning, leakage, grounding issues, over and under voltage, overcharging, excessive current, and overheating. Additionally, the ev level 2 charger automatically shuts off once your vehicle is fully charged, enhancing car safety. Tips: We recommend installing a circuit breaker on your home circuit for added safety measures.
  • Extended 25FT Cable Length---With an impressive 25-foot cable, you can conveniently charge your EV at home or using public charging stations. Its internal copper wires ensure top conductivity, while the TPE flame-retardant jacket adds durability. Plus, this ev charging cable is IP66 waterproof and dustproof, enduring temperatures from -30°C to 45°C.
Bestseller No. 10
EG evgoer Electric Vehicle Charger Level 2 & Level 1, 40Amp 110V-240V Schedule Timer Portable EV Home Charging Station, 12/16/24/32A/40A Adjustable Current 30ft Cable,Compatible with All SAE J1772 EVs
  • 【FASTER CHARGING】Our Level 2 (40Amps, 240V) EV charger charges up to 7 times faster than a standard wall outlet (Level 1), making it quick and effortless to charge your electric vehicle.
  • 【UL STANDARD & SAFE EV CHARGER】The 40A EV charger uses high-quality raw materials, and both the charging gun and the cable are in compliance with UL standards , so you can use it with confidence and safety. Our level 2 EV charger features advanced S-PROTECH technology for safe and smart charging at maximum speed. It is designed to protect against short-circuit, current leakage, grounding, thermal overload, over-charging, and over-current.
  • 【SMARTER CHARGING AND ADJUSTABLE CURRENT】EV charger comes equipped with adjustable current mode and timer feature for more cost-effective charging. The current of Level 2 charger can be adjusted from 12A to 16A for 110V, and from 12A to 40A for 240V (with options of12A,16A,24A, 32A, 40A).Auto Mode maximizes current output for fast charging, while Manual Mode optimizes current output to prolong battery life. Set a timer to charge during off-peak hours and save even more on electricity costs.
  • 【IP66 WATERPROOF AND PORTABLE CHARGING】The 40A EV charger is waterproof and dustproof (IP66) for reliable use in all weather conditions, both indoors and outdoors. It comes with a 110V cable and a custom protective case for safe storage in your vehicle, so you can recharge your EV anywhere - whether you're on a business trip,interviewing family and friends,or traveling. With a 30 FT (9.1 M) cable length from plug to charging gun, giving you the flexibility to park your car wherever you need to.
  • 【WORK WITH ANY EV AND 3-YEAR WARRANTY】The portable EV charger is compatible with all electric vehicles and plug-in hybrids with J1772 connectors, including leading brands such as Tesla charger (need SEAJ1772 adapter,not include), Ford, Hyundai, Kia, Nissan, Chevrolet and more. Our residential EV chargers come with a 3-year limited warranty and lifetime technical support for added peace of mind. We provide 24-hour sales service and free return exchange service.

Last update on 2024-05-27 / Affiliate links / Images from Amazon Product Advertising API

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