Recall 200 – Lithium-Ion Battery May Short Circuit – 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric

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March 1, 2021 NHTSA CAMPAIGN NUMBER: 21V127000

Lithium-Ion Battery May Short Circuit

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

 

NHTSA Campaign Number: 21V127

Manufacturer Hyundai Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 4,696

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2019-2020 Kona Electric and 2020 Ioniq Electric vehicles. The lithium-ion (Li-ion) battery may short-circuit.

 

Remedy

Hyundai will notify owners, and as an interim action, owners have the option to follow provided instructions to perform a battery update through the vehicle’s infotainment system or request a Hyundai dealer to provide the update. Once parts are available, dealers will inspect the Battery System Assembly (BSA), and replace it if necessary. Repairs will be performed free of charge. Owners are advised to park their vehicles outside and away from structures until the interim action is complete. Owners were notified of the safety risk, and the interim action, with a letter mailed April 9, 2021. Final owner notification letters were mailed June 17, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 200.

 

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

 


Q&A

 

Q1: What is the issue?

A1: The subject vehicles are equipped with battery cells manufactured in the LG Energy Solutions China (Nanjing) plant in which the Anode (Negative) tab can be folded. A folded Anode tab in the battery cell could allow the Lithium plating on the Anode tab to contact the Cathode resulting in an electrical short.

 

Q2: What are the affected vehicles?

A2: The subject vehicles include:

  • Approximately 4,694 model year 2019-2020 Hyundai Kona Electric vehicles produced from August 28, 2018 through March 2, 2020.
  • Approximately 2 model year 2020 Hyundai Ioniq Electric vehicles produced from November 8, 2019 through November 11, 2019.

 

Q3: What is the safety concern?

A3: An electrical short internally within battery cell(s) increases the risk of a vehicle fire while parked, charging and/or driving.

 

Q4: Have there been any accidents or injuries?

A4: To date, Hyundai is not aware of any fires or injuries/fatalities in the U.S. attributable to this condition.

 

Q5: What will be done during the recall service at the dealer when the remedy is available?

A5: Remedy is currently available for 19MY and 20MY Kona EV vehicles. The battery system assembly (BSA) will be inspected, and if applicable, may need to be replaced and/or the Battery Management System (BMS) may also need to be updated.

 

Q6: When will owners be notified?

A6: NHTSA has posted this recall. Owners were mailed interim notification letters in April 2021 regarding a remedy not yet available. 19MY owners began receiving remedy available notification beginning in late June 2021 as battery supply became available for their vehicle. 20MY owners previously received a remedy not yet available letter.

With the re-launch of recall 200 TSB including 20MY vehicles, 19MY and 20MY owners will both receive remedy available letters in the coming weeks.

 

Q7: Should customers park these vehicles outside until the recall repair is completed?

A7: Out of an abundance of caution, owners of these vehicles should park them outside until the recall repair is completed. If needed, the customer will be provided a rental vehicle. If battery SOC has been set to 80% (Service Campaign P29) the vehicle can be safely charged and operated, including parking inside.  

 

Q8: Why should customers park their vehicles outdoors?

A8: Customer safety is our top priority. After further review, it was determined that out of an abundance of caution customers should park the vehicles outside until the recall is completed.

 

Q9: If a customer has had the P29 completed, is the vehicle safe to charge and operate? A9: Yes. If the P29 has been completed the vehicle can be safely charged and operated.   

 


Description: Some vehicles may experience a short circuit inside the high voltage battery cell. An electrical short within battery cell(s) increases the risk of a vehicle fire while parked, charging and/or driving. The Battery System Assembly may need to be replaced and/or the Battery Management System (BMS) software may need to be updated.

 

Applicable Vehicles:  Certain2019MY Kona Electric (OS EV) vehicles

 

Parts Information:

Part Number Year Description Photo Quantity Remarks
NOTE:  Battery System Assembly (BSA) replacement must have Warranty PA approval prior to ordering and replacing the BSA.  Order CSP with VIN and after PA Approval.

NOTE: Enter P/N order ending with AS, however the parts system may supersede it to end in RW or RA.

37501-K4000AS 2019MY Battery System Assembly (BSA)   1

 

All 2019MY
37501-K4001AS 2020MY Battery System Assembly (BSA) (Unheated Battery) Identify the  correct 20MY Battery  from the vehicle’s  Battery Label, but add AS to end of the P/N.
37501-K4051AS Battery System Assembly (BSA) (Heated Battery)
NOTE:  Technician should confirm color of coolant in the subject vehicle.  Do not mix coolant colors.
00232-19010 Vehicle built before 5/7/19. Green Coolant (standard coolant) 1 qty. x 4L  bottle Mix 50/50 with water.
00232-19091 Vehicle built 5/7/19 or later. Blue Coolant (low conductivity type)       3 qty. x 2L Bottle Do not mix  with water.
37535-GI500QQH 2019-2020MY Bolt & Washer Assembly 18 Must replace and discard  the old bolts.
37535-Q4050QQH 4

 

 

YouTube video

 


RECALL 200 ATTACHMENT A

CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

  • March 2019 – August 2019 

HMC received three reports of Kona Electric vehicles catching fire while parked in the Korean market. All vehicles involved were reportedly parked with full state-of-charge in the vehicle’s Li-ion battery. HMC conducted a search globally and found two similar incidents in Canada, and one incident in Europe. HMC reviewed and investigated these incidents with the Korea Automobile Testing & Research Institute (“KATRI”) and Transport Canada (“TC”) respectively.

 

  • September 2019 to March 2020 

HMC and KATRI continued to jointly investigate known fire cases through regular discussions on KATRI’s opened defect investigation. In March 2020, a service campaign was launched globally to upgrade the BMS software for automated early detection of abnormalities in the Li-ion battery state while the vehicle is parked. This software update was developed jointly with the Tier 2 battery cell supplier, LG Chemical, as a fail-safe “level-up” countermeasure. HMC began collecting and analyzing Li-ion batteries replaced under the campaign to continue their investigation.

 

  • April 2020 – October 2020

HMC received an additional seven reports globally of fires on parked Kona Electric vehicles. Six of these incidents occurred in Korea while one occurred in Europe. HMC continued joint review and study of these incidents with KATRI. Hyundai continued its investigation by studying the effects of electrical shorting in the Liion battery. While unsuccessful in duplicating the actual fire condition, HMC confirmed that the BMS software update associated with the previous service campaign could detect the early onset of an internal short, illuminate a warning light, and limit the vehicle’s power until the diagnostic code is cleared.

 

  • October 2020

HMC informed HMA of their findings on October 7, 2020. HMA convened its NASDA on October 8, 2020 and decided to conduct a safety recall campaign to repair all potentially affected vehicles in the U.S.

 

On October 17, 2020, a Kona EV vehicle with the updated software caught fire in Korea at full state of charge.  The investigation into the fire was unable to determine a root cause due to the severe damage to the Battery System Assembly (BSA).

 

  • January – February 2021

Hyundai became aware of a Kona EV vehicle with the updated BMS software that caught fire while at full state of charge. The investigation into the cause of the fire revealed an internal short within the battery cells. Continuing its investigation into the cause of the internal short circuit, HMC determined that a folded Anode tab in the battery cell could result in Lithium plating on the Anode tab to contact and short circuit to the Cathode. HMC notified HMA of their findings.

 

Based on the information received, on February 23, 2021, HMA convened its North American Safety Decision Authority and decided to conduct a safety recall campaign to repair all potentially affected vehicles in the Canadian and U.S. markets.

 

To date, Hyundai is unaware of any fires/injuries in the U.S. market related to this condition.

 


 


3 Affected Products

Vehicles

MAKE MODEL YEAR
HYUNDAI IONIQ ELECTRIC 2020
HYUNDAI KONA ELECTRIC 2019-2020

 


13 Associated Documents

Recall Quarterly Report #1, 2021-2

RCLQRT-21V127-9895.PDF 211.137KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V127-3156.pdf 458.9KB

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Remedy Instructions and TSB

RCRIT-21V127-3010.pdf 1480.221KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V127-5956.pdf 173.937KB

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Recall Acknowledgement

RCAK-21V127-1997.pdf 691.143KB

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CHRONOLOGY

RMISC-21V127-8743.pdf 83.088KB

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Defect Notice 573 Report

RCLRPT-21V127-1095.PDF 214.08KB

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Recall 573 Report – Amendment 1

RCLRPT-21V127-4027.PDF 214.141KB

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Remedy Instructions and TSB

RCRIT-21V127-9238.pdf 2420.116KB

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Manufacturer Notices(to Dealers,etc) – Recall 200 – 19MY-20MY KONA ELECTRIC (OS EV) BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND BATTERY REPLACEMENT (TSB# 21-01-046H-2): Remedy Available, December 20, 2021

RCMN-21V127-5335.pdf 2887.999KB

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Manufacturer Notices(to Dealers,etc) – Recall 200 for 19MY-20MY KONA ELECTRIC (OS EV) BATTERY INSPECTION, BMS SOFTWARE UPDATE AND BATTERY REPLACEMENT (TSB# 21-01-046H-1) Remedy Available

RCMN-21V127-9103.pdf 2779.449KB

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Manufacturer Notices(to Dealers,etc) – 2019MY KONA ELECTRIC (OS EV) BATTERY MANAGEMENT SYSTEM SOFTWARE UPDATE AND BATTERY SYSTEM ASSEMBLY REPLACEMENT

RCMN-21V127-9910.pdf 1453.337KB

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V127-9475.PDF 211.331KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V127&docType=RCL

 


 

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.

 

Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light CarDAQ-Plus
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light CarDAQ-M
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light SuperGoose-Plus J2534 OEM Vehicle Interface
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light RAP2 OEM J2534 Remote Reprogramming Tool
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909
Recall 200 - Lithium-Ion Battery May Short Circuit - 2019-2020 Hyundai Kona Electric & 2020 Ioniq Electric | small light GODIAG J2534

 

https://www.hyundaitechinfo.com/external/j2534_diagnostics_and_programming.aspx

 

www.hyundaitechinfo.com

 


 

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