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

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Recall 196 Dealer Best Practice
Date: February 05, 2021
Attn: Dealer Principal/General Manager/Service Manager/Parts Manager
Subject: Recall 196: Kona EV Battery System – Remedy Now Available (TSB# 21-01-006H supersedes TSB #20-01-042H-1) v4
Updates To This Document
Date
• Update – Revised TSB with updates to the Service Procedure, add HV battery replacement, and update the Warranty section with additional OP codes.
2/05/21
***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 is conducting a safety recall in the United States to address a condition with the high-voltage battery system in certain model year 2019-2020 Hyundai Kona Electric vehicles produced for sale in the U.S. market.
The affected vehicles include:
• Certain 2019-2020MY Kona Electric (OS EV)
Hyundai is initiating this action to ensure the safety and compliance of its vehicles and the continued satisfaction of Hyundai customers.
IMPORTANT NOTE: Service Campaign 960 has been terminated in accordance with Recall 196 having the most updated software for the affected vehicles.
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.
Service Action
Reservation – Always check the Vehicle Information Screen in WebDCS for open campaigns and recalls, and advise the customer on time requirements.
• Important: If there are affected vehicles in Dealer’s stock inventory, vehicles must be held at the dealership and not sold until this recall repair has been completed. Dealer will forfeit incentives if vehicles with an open recall are sold to customers.
Readiness – Review this announcement and the accompanying FAQs with all Service and Parts staff including Reservationist/BDC. Also, complete all applicable training, check your reservation capacity settings (you can set separate capacities for every recall/campaign), confirm email addresses for campaign appointments, and that you have all necessary tools, campaign parts and shop equipment as needed.
• Recommended Level of Technician Certification and/or Completed Coursework to perform TSB work:
o Hyundai Master Technician with Hybrid Vehicle Training – Classroom (#SVCHHHYBVEHTRN218_800) and Electric Vehicle Battery R&I Training – Web ($SVCHEVHVBRWIW19_811) courses completed
• Eco-friendly vehicle owners should be provided an equivalent eco-friendly SRC, or alternative transportation, as needed.
• Please ensure to park these vehicles outdoors and/or away from structures until the vehicle is remedied.
Reception – Always check the Vehicle Information Screen in WebDCS for open campaigns and recalls, and print a copy for technicians. Provide SRC or an alternative vehicle, as needed. If a customer has declined the campaign, note this on the repair order and request the customer’s signature next to the statement.
• When a vehicle arrives at the Service Department, access Hyundai Motor America’s “Vehicle Information Screen (VIS)” screen via WEBDCS to identify open Campaigns.
Repair – Always plug in the GDS before starting the repair. Make sure to complete an MPI on all vehicles and Quality Control your work.
• WARNING:
o 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.
o Stock vehicles are prone to low battery condition. Operate a stock vehicle at ready on for 20 minutes prior to starting the Multi-ECU update.
o This will ensure 12V battery will be charged to an adequate level, preventing potential update failure or controller damage.
o If DTCs are detected in the BMS system, follow 196’s TSB for proper instructions related to repairing the vehicle or potential high voltage battery replacement.
o Do not proceed with ECM updates before diagnosing and repairing all DTCs in the BMS System.
o Check VIS to determine if Campaign 960 has already been completed. If an attempt is made to update the IGPM and MCU on a vehicle that had Campaign 960 completed previously, the GDS will show that these two systems already have the latest software installed.
• 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. After successful completion of the applicable system updates, search all systems for DTC codes:
o If no DTCs are found, the procedure is complete.
o If DTCs are detected in the BMS system, follow 196’s TSB for proper instructions related to repairing the vehicle or potential high voltage battery replacement.
Return – Review all completed campaigns/recalls and repairs to answer any customer questions. Also, schedule the customer’s next service.
Reconnect – Follow up for customer satisfaction.
Parts
• Please review the TSB for parts information if a battery replacement is needed and for GDS 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
• In the case that the DTC P1AA600 appears prior to or after the dealer performs the applicable software updates or if the customer comes back to the dealer with DTC P1AA600, dealer will need to replace the high voltage battery and update the BMS software, if applicable. Dealer may submit a second campaign claim for battery replacement under Recall 196.
Customer Notification
This recall has been posted with NHTSA. Owners have been mailed notification letters beginning in mid-December 2020.
Thank you for your prompt attention to this important matter and continued commitment to Hyundai customers.
Hyundai Motor America
Key Contact Information
Dealer Support
Contact Information
Description
Parts
[email protected]
18005454515
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
[email protected]
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
AutoLoop Technical Support
[email protected]
1-877-850-2010
Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes
CDK Technical Support
https://serviceconnect.support.cdk.com/
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/recall
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
SRC Documentation: www.HyundaiDealer.com > Service tab > Documents Library > Service Rental Car
TSD: www.HyundaiDealer.com > Service tab > SRC Fleet Mgmt Software
Insurance: www.HyundaiDealer.com > Service tab > SRC Insurance
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
NHTSA Website
www.safercar.gov
Appendix
Updates To This Document
Date
• Update – Remedy Now Available (TSB #20-01-042H) and termination of Service Campaign 960 with the launch of Recall 196
10/30/20
• Initial Communications to Dealers – Remedy Not Yet Available
10/14/20

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This notice applies to your Hyundai, VIN: XXXXXXXXXXXXXXXXX
Dear <FirstName LastName,>
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Hyundai has decided that a defect which relates to motor vehicle safety exists in your vehicle, with the VIN shown above. Hyundai is conducting a safety recall in the United States to address a condition with the high-voltage battery system in certain model year 2019 – 2020 Hyundai Kona Electric vehicles produced by Hyundai Motor Company (“HMC”) for sale in the U.S. market.
What is the problem?
The high-voltage battery system in the subject vehicles may have been produced with internal damage to certain cells of the lithium-ion battery that could increase the risk of an electrical short circuit. An electrical short in Li-ion battery could increase the risk of a fire. Hyundai is continuing to actively investigate this condition for identification of a specific root cause.
What will Hyundai do?
Your Hyundai dealer will inspect and replace 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 procedure will be performed at NO CHARGE to you.
What should you do?
Please contact your nearest Hyundai dealer to schedule the recall repair as soon as possible.
Owners should park their vehicles outside and/or away from structures until the recall repair is completed. If the Malfunction Indicator Light is illuminated in your vehicle, you should seek service at your Hyundai dealer as soon as possible. The actual time required to perform the repair will take less than one hour, however your vehicle may be needed longer. Therefore, we recommend scheduling a service appointment to minimize inconvenience.
If you have other questions
IfIf you require further assistance, you may contact the Hyundai Customer Care Center at 1-855-371-9460. If you believe that the dealer or Hyundai has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov.
Thank you for your attention to this important safety matter. We apologize for any inconvenience this may have caused you.
Hyundai Motor America
Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937
IMPORTANT SAFETY RECALL
2019 – 2020 Kona EV
High Voltage Battery System
Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”
NHTSA Recall Number: 20V-630
Hyundai Recall Number: 196
This is an important Safety Recall.
• Please contact your nearest Hyundai dealer to schedule the repair as soon as possible.
• This repair will be performed at NO CHARGE to you.
• To locate your nearest Hyundai dealer and schedule your appointment please visit:
www.HyundaiUSA.com/Campaign196

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