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

SEOCONTENT-START

This notice applies to your Hyundai, VIN:
Dear
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
and Canada to address a potential condition with the electric vehicle (“EV”) lithium-ion (“Li-ion”) battery that could result in a fire in
certain model year 2019 –2020 Kona EV.
The purpose of this letter is to explain what the recall is about and to keep you informed of Hyundai’s recall implementation plan. We are
currently making preparations to implement the safety recall remedy which when available, will be performed at no cost to you. We will
send you another notification when the remedy is available.
What is the problem?
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. An electrical short internally within battery cell(s) increases the risk of a vehicle fire while parked, charging
and/or driving.
Hyundai previously issued Recall 196 which provided Hyundai dealers the ability to update software and inspect the lithium-ion battery,
and replace if necessary, for Kona EV. Hyundai is now amending Recall 196 with Recall 200 and add additional remedies.
What should you do in the interim?
We appreciate your patience. Hyundai is currently making preparations to implement the recall remedy. You will receive a second notification
letter when the remedy is available, and the Battery System Assembly will be inspected, and replaced — if necessary. If the Malfunction
Indicator Light is illuminated in your vehicle, you should seek service at your Hyundai dealer as soon as possible. Customers should park
and charge outside and away from structures until they can reduce their vehicle’s “Max. % Charge” level to 80% as described below.
For updated information regarding this recall, please visit:
www.HyundaiUSA.com/Campaign200
In the meantime, owners are recommended to perform the following:
• Adjust or confirm your vehicle’s “Max. % Charge” level to 80%. This can be done manually at home using the infotainment system with
these steps:
o Turn the vehicle ignition ON without starting the engine.
o Depending on radio select: EV on display screen (7 in.) or battery display (10.25 in.).
o Select Energy Information.
o Select DC Charger.
o Press the Minus (-) Sign until the charger percentage reaches 80%.
o Select OK when complete.
o Perform the same steps once more for the AC Charger.
o Both the DC and AC charge percentage will now be set and displayed at 80%.
o See instructional video www.youtube.com/watch?v=dk-FrxW5bRM which can be viewed by using this QR code.
• If your vehicle is currently subscribed to Bluelink, Hyundai will attempt to remotely set your “Max. % Charge” to 80% within the next
week. You can verify the setting following the steps above.
• You must go to the dealership to verify or adjust “Max. % Charge” level reduced to 80%. Once verified at the dealership you will
receive a $200 gift card due to the inconvenience of reduction of range. Please provide the dealer with a valid email address and allow
10 business days for processing.
• If you cannot adjust or go to the dealership to achieve “Max. % Charge” level to 80%, park and charge your vehicle outside and/or
away from structures until the “Max. % Charge” level has been reduced to 80%.
If you have other questions
If 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 (INTERIM NOTICE)
2019 – 2020 Kona EV
Lithium-ion Battery
NHTSA Recall Number: 21V-127
Hyundai Recall Number: 200
Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”
This is an important Safety Recall.
• We are currently preparing the remedy. We will notify you when the remedy is ready.
• For updated information, you can visit:
www.HyundaiUSA.com/Campaign200
If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the
lessee within ten days.
No longer own this vehicle?
Changes to your name, address, or if you no longer own this vehicle — Update your information online at:
https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/update-vehicle-ownership.html
You can easily connect to this web page by using your cell phone to point your camera (or QR code reader app) at the code below. Then
select the link which will be displayed on your phone.
Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937

***************************************************************************************************

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
Technical Service Bulletin
GROUP
NUMBER
RECALL
21-01-046H-2
DATE
MODEL(S)
DECEMBER, 2021
Kona Electric
(OS EV)
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
This bulletin has been revised to add a QR code and link that refers to a video of the TSB procedure. Note is added to Parts Information that Parts System may supersede an AS battery to RW or RA. Additional op codes have also been added to the Warranty Information table to specify replacement of battery ending in ‘RW’ or ‘RA’, if applicable.
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 (BSA) will be inspected, and if applicable may need to be replaced and/or the Battery Management System (BMS) software may need to be updated. Applicable Vehicles: Certain 2019-2020MY Kona Electric (OS EV) vehicles
Scan this QR code or open this link for video of this TSB: https://vimeo.com/597455357/a559bdea14
SUBJECT:
*****Dealer Stock and Retail Vehicles
Dealers must perform this Recall Campaign on all affected vehicles prior to customer retail delivery
and whenever an aff ected 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) VIS)” scre en via WEBDCS to identify open C ampaigns.
 IMPORTANT
 Follow the flowchart on pages 2 2-3 for the overall service procedure summary and refer to each specific section mentioned on the flowchart as more details are needed.
 Refer to TSB 21 21-EE -002H002H-1 “EV Battery Approval, Handling , and Replacement Procedures ” for
specifics related to BSA replacement including required tools and training training. The to ol form in the TSB 21 -EE -002H002H-1 only needs to be completed and submitted one time for tools approval.
 Refer to parts and warranty information of pa page -4 when ordering BSA after Prior Approval ( PA ) and for claim information r elated to this TSB.
 Campaigns T5V and /or P29 if still open for the vehicle, will not need to be completed once Recall
200 is fully completed . However P29 is required when interim releasing a vehicle waiting for a BSA.
 Dealers only having in ground center floor lifts cannot replace an EV Battery . Cont act your regi region to todiscuss how to accommodate a customer that requires a BSA replacement.
IMPORTANT
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 2 of 21
SUBJECT:
SUBJECT:
To watch video of the TSB procedure, scan QR code or open: https://vimeo.com/597455357/a559bdea14
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 3 of 21
SUBJECT:
SUBJECT:
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 4 of 21
SUBJECT:
SUBJECT:
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
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 5 of 21
SUBJECT:
SUBJECT:
Warranty Information: Model Op. Code Operation Op. Time Causal Part Nature Cause
Kona Electric
(OS EV)
11D043R2
BAR CODE READING AND BMS UPDATE
0.5 M/H
375A0-K4000
D22
ZZ3
11D043R3
BAR CODE READING AND
BSA REPLACEMENT
(Parts ending in ‘AS’ used)
3.8 M/H
37501-K4000AS
11D043R4
BAR CODE READING, BMS UPDATE AND BSA REPLACEMENT
(Parts ending in ‘AS’ used)
4.1 M/H
37501-K4000AS
11D043R6
BAR CODE READING AND
BSA REPLACEMENT
(Parts ending in ‘RW’ used)
3.8 M/H
37501-K4000RW
11D043R7
BAR CODE READING, BMS UPDATE AND BSA REPLACEMENT
(Parts ending in ‘RW’ used)
4.1 M/H
37501-K4000RW
11D043R8
BAR CODE READING AND
BSA REPLACEMENT
(Parts ending in ‘RA’ used)
3.8 M/H
37501-K4000RA
11D043R9
BAR CODE READING, BMS UPDATE AND BSA REPLACEMENT
(Parts ending in ‘RA’ used)
4.1 M/H
37501-K4000RA
NOTE 1: Additional reimbursement of 0.3 M/H has been included for 11D043R3~11D043R9 claims for unpackaging/handling/repacking the EV battery per procedure of TSB 21-EE-002H-1, and Max Charge %SOC adjustment to 80% if needed to interim release a non-incident vehicle prior to parts arrival. If Service Campaign P29 is also open on the vehicle, please ensure a campaign claim is also submitted for P29 to close it. NOTE 2: Submit Claim on Campaign Claim Entry Screen. NOTE 3: If a part not covered by this campaign 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. NOTE 4: Failure to include the necessary original and replacement battery labels in STUI according to the flowchart on pages 2-3 will result in delay of claim payment.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 6 of 21
SUBJECT:
SUBJECT:
Service Procedure: NOTE: Follow the flowchart of pages 2-3 and refer to these sections as needed.
A.
GDS Tablet STUI Camera Photo Uploads to HMA as required:
A-1
Connect GDS STUI and VCI with ignition ON.
Perform AUTO VIN to ensure that vehicle’s VIN is captured.
A-2.
Locate the battery label on the Battery System Assembly (BSA) at the rear of the vehicle as shown.
A-3.
Use STUI camera photo upload function to Save and Submit photo to HMA of the BSA labels.
IMPORTANT: Use a shop light to light up the battery label area and tap the tablet screen at the image of the label to ensure a clear image of the label. The S/N next to the barcode must be clear and visible.
Following Photos are required to be submitted to HMA by STUI:
BSA Replacement Cases:
• Original Battery Label
• Replacement Battery Label.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 7 of 21
SUBJECT:
SUBJECT:
B.
BATTERY INSPECTION BY GDS:
B-1.
• Make sure VCI is connected to the vehicle.
• Keep ignition ON.
• Within GDS vehicle selection screen select correct vehicle (A).
• Perform AUTO VIN (B).
B-2.
• Select S/W Management from the GDS Home Screen.
• Select EV Battery System.
• Select the Menu item as shown by (C) Check to cathode tab isolation coating of EV battery pack.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 8 of 21
SUBJECT:
SUBJECT:
B-3.
Note the instructions and select OK.
B-4
• The following result screen will display if by the VIN check it is determined only a BMS Update may be required.
NOTE: Per known vehicle production records the BSA already had the countermeasure cathode tab isolation coating, so BSA does not need to be replaced.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 9 of 21
SUBJECT:
SUBJECT:
• The following result screen will display if by VIN check only a result is determined to Replace BSA.
Warranty PA Approval:
• The GDS result should be automatically submitted to Warranty PA so they will be able to verify whether or not a vehicle qualifies for Replace BSA.
• It is recommended as a backup record, Print the result screen to attach to the Repair Order, or save GDS screenshot on the tablet.
B-5.
This screen will occur when it is not possible to determine a result based on VIN only.
Inspection of the battery label will then need to occur to be able to determine a result.
The screen identifies where to locate the Battery Label on the vehicle.
Select OK to continue.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 10 of 21
SUBJECT:
SUBJECT:
B-6.
Attempt to scan the battery label barcode locating it within the scan window (E) and with the red line inside the scan window oriented so it is across the length of the barcode.
Use a shop light to light the battery label area. NOTE: The vertical position of the battery label on the back of the battery varies by vehicle. Depending on position of the battery label try these 2 different ways to attempt to scan:
• When battery label is lower down on the back of the battery, and is visible from below. Try to scan from below like this:
• When battery label is higher up on the back of the battery, it is difficult to view behind the rear cross member. Try scanning with the tablet in between the rear cross member and rear stabilizer bar like this:
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 11 of 21
SUBJECT:
SUBJECT:
NOTE: It may prove impossible to achieve a successful scan of the barcode using some earlier level GDS tablets, with poor condition of the battery label, or with difficulty to access position of the label.
• If bar code recognition is not possible by the GDS scan attempt, press the Manual button (F).
• Enter the 15-digit battery serial number (S/N) located next to the barcode in to the GDS field (G) and select OK.
NOTE: If you are having difficulty reading the 15-digit S/N on the vehicle, use a phone to take a photo of the battery label and zoom in to view the S/N.
• Select OK to continue.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 12 of 21
SUBJECT:
SUBJECT:
B-7.
• The following result screen will display if by S/N check it is determined only a BMS Update may be required.
NOTE: This result will not require BSA replacement, only BMS Update needs to be performed for the Recall 200.
• Select OK to submit the result to HMA
• The following result screen will display if by S/N check it is determined to Replace BSA.
IMPORTANT for Warranty PA Approval:
• The GDS result will be automatically submitted to Warranty PA so they will be able to verify whether or not a vehicle qualifies for Replace BSA.
• It is recommended as a backup record, Print the result screen to attach to the Repair Order, or save GDS screenshot on the tablet.
• Select OK to submit the result to HMA.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 13 of 21
SUBJECT:
SUBJECT:
C.
BATTERY SYSTEM ASSEMBLY (BSA) REPLACEMENT:
• Refer to TSB 21-EE-002H-1 for the complete instructions for EV Battery Approval, Handling, and Replacement Procedures.
• Battery System Assembly (BSA) can only be ordered and replaced once Warranty PA approval has been secured.
D.
GDS AUTO MODE BMS UPDATE PROCEDURE: System Event # Description
BMS
707
OS EV High Voltage Battery Update or Replacement (2nd Recall)
D-1.
Select ECU Upgrade on the initial screen after ensuring the correct vehicle and VIN information.
D-2.
Select Auto Mode.
D-3.
Select the BMS system.
D-4.
Select ID check.
D-5.
The GDS will read the current ROM ID in vehicle and check for the newest upgrade event.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 14 of 21
SUBJECT:
SUBJECT:
➢ NOTE: The following screen will appear had the BMS Update already been applied. BMS Upgrade is not required so do not include a claim for BMS Upgrade.
➢ Skip to step E to adjust the AVN setting Max Charge % back to 100%
➢ If the BMS Upgrade event is required, GDS will read the current ROM ID in vehicle and display the latest upgrade event.
D-6.
Select the upgrade event,
“707.OS EV High Voltage Battery Update or Replacement (2nd Recall)”.
D-7.
The vehicle battery voltage is checked to make sure it is at least 12 volts to assure reliable upgrade results. Click OK if the results indicate voltage is ok.
D-8.
Upgrade (1/2) will begin and progress until 100% is reached.
D-9.
Upgrade (2/2) will begin and progress until 100% is reached.
If battery voltage is below 12 voltages as
If battery voltage is below 12 voltages as below, click BACK and then below, click BACK and then operate the operate the vehicle in Ready mode for a few minutes vehicle in Ready mode for a few minutes to to assure an adequate battery charge state for assure an adequate battery charge state for reliable upgrade results.reliable upgrade results.
NOTICE
NOTICE
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 15 of 21
SUBJECT:
SUBJECT:
D-10.
Turn the ignition key off for 10 seconds, place it back in the key on position and then tab OK to continue according to information displayed on the screen.
D.11
Select OK on the final screen which indicates
upgrade is complete.
D-12.
Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the upgrade and clear the DTC(s) present.
Set the vehicle in Ready mode to confirm proper operation of the vehicle.
E.
Adjust the AVN system Max Charge % settings for both DC Charger and AC Charger back to 100% in the Energy Information screen.
F.
Refer to TSB 21-EE-003H for the procedure to prepare and arrange for battery core pickup.
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 16 of 21
SUBJECT:
SUBJECT:
ROM ID Information Table:
BMS P/NO ROM ID PREVIOUS NEW
375A0-K4050
5300
6820
5400
5500
5700
5800
5900
6000
6020
6040
6050
6060
6070
6080
6090
6100
375A0-K4000
5302
6822
5402
5502
5702
5802
5902
6002
6022
6042
6052
6062
6072
6082
6092
6102
375A0-K4450
5304
6824
5404
5504
5704
5804
5904
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 17 of 21
SUBJECT:
SUBJECT:
375A0-K4450
6004
6824
6024
6044
6054
6064
6074
6084
6094
6104
5306
375A0-K4400
5406
6826
5506
5706
5806
5906
6006
6026
6046
6056
6066
6076
6086
6096
6106
6200
375A0-K4051
6220
6820
6240
6540
6550
6560
6570
6580
6590
6600
6202
375A0-K4001
6222
6822
6242
6542
6552
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 18 of 21
SUBJECT:
SUBJECT:
375A0-K4001
6562
6822
6572
6582
6592
6602
375A0-K4451
6204
6824
6224
6244
6524
6544
6554
6564
6574
6584
6594
6604
375A0-K4401
6206
6826
6226
6246
6526
6546
6556
6566
6576
6586
6596
6606
375A0-K4052
6400
6820
6500
6700
6730
6740
6770
6780
6790
6800
6900
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 19 of 21
SUBJECT:
SUBJECT:
375A0-K4002
6402
6822
6502
6702
6732
6742
6772
6782
6792
6802
6902
375A0-K4452
6504
6824
6734
6744
6774
6784
6794
6804
6904
375A0-K4402
6506
6826
6736
6746
6776
6786
6796
6806
6906
375A0-K4053
6960
7040
6980
7020
375A0-K4003
6962
7042
6982
7022
375A0-K4453
6964
7044
6984
7024
375A0-K4403
6966
7046
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 20 of 21
SUBJECT:
SUBJECT:
F.
MANUAL UPGRADE PROCEDURE USING GDS-MOBILE
G-1.
Within the upgrade screen, select Manual Mode, then select upgrade event.

• The manual upgrade should The manual upgrade should only be performedonly be performed ifif the automatic upgrade fails.the automatic upgrade fails.

• If automatic upgrade fails, turn the ignition key off for about 10 seconds, If automatic upgrade fails, turn the ignition key off for about 10 seconds, then then place it back place it back toto the on position to reset the control unit before performing manual upgrade.the on position to reset the control unit before performing manual upgrade.
NOTICE
NOTICE
KONA EV BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND
BATTERY REPLACEMENT (RECALL 200)
TSB #: 21-01-046H-2 Page 21 of 21
SUBJECT:
SUBJECT:
G-2.
It is important to select the correct BMS part number with reference to the above ROM ID Information Table and select OK.
G-3.
Enter the password from the table below, then touch OK.
# 707.OS EV High Voltage Battery Update or Replacement (2nd Recall)
Password Information Table: MENU PASSWORD OS EV BMS 375A0-K4050 4050 OS EV BMS 375A0-K4000 4000 OS EV BMS 375A0-K4450 4450 OS EV BMS 375A0-K4400 4400 OS EV BMS 375A0-K4051 4051 OS EV BMS 375A0-K4001 4001 OS EV BMS 375A0-K4451 4451 OS EV BMS 375A0-K4401 4401 OS EV BMS 375A0-K4052 4052 OS EV BMS 375A0-K4002 4002 OS EV BMS 375A0-K4452 4452 OS EV BMS 375A0-K4402 4402 OS EV BMS 375A0-K4053 4054 OS EV BMS 375A0-K4003 4004 OS EV BMS 375A0-K4453 4454 OS EV BMS 375A0-K4403 4404
G-4.
The remaining steps are identical to the steps located in the Automatic Upgrade Procedure

************************************************************************************************

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 and Canada to address a potential condition with the electric vehicle (“EV”) lithium-ion (“Li-ion’) battery that could result in a fire in certain model year 2019 – 2020 Kona EV.
What is the problem?
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. An electrical short internally within battery cell(s) increases the risk of a vehicle fire while parked, charging and/or driving.
Hyundai previously issued Recall 196 which provided Hyundai dealers the ability to update software and inspect the lithium-ion battery, and replace if necessary, for Kona EV. Hyundai is now amending Recall 196 with Recall 200 and adding additional remedies.
What will Hyundai do?
Your Hyundai dealer will update the software of the Battery Management System (BMS) or replace the Battery System Assembly (BSA), if necessary. 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.
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 the Malfunction Indicator Light is illuminated in your vehicle, you should seek service at your Hyundai dealer as soon as possible.
You should park and charge outside and away from structures until the repair is completed.
If you have other questions
If 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
Lithium-ion Battery
Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”
NHTSA Recall Number: 21V-127
Hyundai Recall Number: 200
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/Campaign200
Window is 4.5″ x 1.25″0.75″ from bottom0.75″ from leftIMPORTANT SAFETY RECALL2012 Accent, 2011 – 2012 Elantra, 2011 – 2012 Sonata Hybrid, 2012 Veloster Tire Mobility KitPRESORTEDFIRST-CLASS MAILU.S. POSTAGEPAIDHYUNDAIHyundai Motor AmericaP.O. Box 2704Huntington Beach, CA 92647Recall-Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937
If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice
to the lessee within ten days.
Reimbursement Notification
If you paid for repairs related to this recall prior to receiving this notification letter, you may submit your reimbursement request electronically or obtain additional information at www.HyundaiUSA.com/Campaign200 or 1-855-371-9460.
No longer own this vehicle?
Changes to your name, address, or if you no longer own this vehicle — Update your information online at:
https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/update-vehicle-ownership.html
You can easily connect to this web page by using your cell phone to point your camera (or QR code reader app) at the code below. Then select the link which will be displayed on your phone.
IMPORTANT SAFETY RECALL
2019 – 2020 Kona EV
Lithium-ion Battery
PRESORTED
FIRST-CLASS MAIL
U.S. POSTAGE
PAID
HYUNDAI
Hyundai Motor America
P.O. Box 2704
Huntington Beach, CA 92647
Recall-200-RA_Env-HB_9nHalfx6_PMS_04-21_v2-Bleed
Black – 654 – 185

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Page 1 of 25
HMA Recall 200 – Dealer Best Practice
Date: December 20, 2021
Attn: Dealer Principal/General Manager/Service Manager/Parts Manager
Subject: Recall 200 – 19MY-20MY KONA ELECTRIC (OS EV) BATTERY INSPECTION, BMS SOFTWARE UPDATE, AND BATTERY
REPLACEMENT (TSB# 21-01-046H-2): Remedy Available
Table of Contents
Updates To This Document ……………………………………………………………………………………………………………………………………………………. 2
Affected Vehicles …………………………………………………………………………………………………………………………………………………………………… 2
Customer Handling ……………………………………………………………………………………………………………………………………………………………….. 2
The Problem ………………………………………………………………………………………………………………………………………………………………………. 2
Interim Solution (Service Campaign P29) ……………………………………………………………………………………………………………………………….. 3
Recall 200 Flowchart ……………………………………………………………………………………………………………………………………………………………… 4
EV Battery Handling ………………………………………………………………………………………………………………………………………………………………. 6
Customer Talk Tracks ……………………………………………………………………………………………………………………………………………………………. 7
Setting Max Charge Instructions for Service Campaign P29 ……………………………………………………………………………………………………. 10
Service Actions ……………………………………………………………………………………………………………………………………………………………………. 10
Warranty ……………………………………………………………………………………………………………………………………………………………………………….12
Parts …………………………………………………………………………………………………………………………………………………………………………………… 12
Special Tools ..…………………………………………………………………………………………………………………………………………..13
Sample Dealer Special Tool Acknowledgement …………………………………..………………………………………………………………14
Sample Field Special Tool Verification ………………………………………………..……………………………………………………………14
Customer Notification …………………………………………………………………………………………………………………………………………………………… 15
Q&A ……………………………………………………………………………………………………………………………………………………………………………………. 16
Key Contact Information ………………………………………………………………………………………………………………………………………………………. 17
Appendix …………………………………………………………………………………………………………………………………………………………………………….. 18
……………………………………………………………………………………………………………….. 19
……………………………………………………………………………… 20
………………………………………………………………………………………………………………………… 22
………………………………………………………………………………………………………………………………………… 23
………………………………………………………………………………….. 24
………………………………………………………………………………………………………………………….. 25
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1. Parts Information and Parts Ordering
2. Receiving and Handling of EV Battery at the Dealership
3. Storing and Stacking EV Battery
4. Used EV Battery Return
5. Submitting a return/ claim for a Damaged EV Battery
If you have any questions regarding this bulletin, please refer to the Mobis Parts Portal or contact the
Parts Help desk at: 1-800-545-4515.
Page 2 of 25
Key Updates to This Document for Recall 200 Date
• Once Recall 200 has been completed, set the vehicle Max Charge back to 100%
• Updated TSB#: 21-01-046H-2: Adding a QR code and link that refers to a video of the TSB procedure
• Additional note added under Parts Information that Parts system may supersede a battery ending in ‘AS’ to one
ending in ‘RW’ or ‘RA’, depending on availability
• Additional op codes have been added to the Warranty Information table to specify replacement of battery
ending in ‘RW’ or ‘RA’, if applicable
12/20/21
***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 must 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.
When a vehicle arrives at the Service Department, access Hyundai Motor America’s “Vehicle Information” screen via WEBDCS to
identify open campaigns and recalls.
Affected Vehicles
• Certain 2019MY Kona Electric (OS EV) vehicles – REMEDY AVAILABLE
• Certain 2020MY Kona Electric (OS EV) vehicles – REMEDY AVAILABLE
Customer Handling
Due to the complexity of Recall 200, there are many factors that need to be understood when handling a customer affected by this
recall.
Now that 20MY vehicles are being added, we will no longer use the flag “Campaign 200X” to indicate that a battery/remedy is available
for a particular vehicle. The Recall 200 TSB has been updated to TSB# 21-01-046H-2 so that Technicians will perform a new GDS
battery inspection function to determine which vehicles will need battery system assembly (BSA) replacements. Follow the procedure
found in the TSB 21-01-046H-2 flowchart on pages 2-3.
• If the GDS result is “Replace BSA” This result will automatically generate a Prior Approval (PA) in saved (draft) status.
Then, the dealer must submit the PA to be able to order a BSA. If not on hand, EV battery replacement tools must be obtained
by dealer by completing and sending in a Tool Acknowledgment Form; please see TSB 21-EE-002H-1 for tool information.
o Some vehicles based on the GDS result will only require a BMS Update and not have to replace BSA. In this case
the GDS battery inspection function determined the vehicle already has the latest BSA; either vehicle was built that
way or latest BSA had already been installed at a prior service.
o In the meantime, if a customer comes in with an open Recall 200 and the GDS battery inspection function result is
“Replace BSA”, but dealer does not have tools or training, follow the TSB-21-01-046H-2 flowchart to be able to obtain
tools and seek PA approval to be able to order a BSA.
o Vehicles that do not have DTC P1AA6/EV Warning Battery Light ON) should be released back to customer until
tools and parts are on hand, but it is important to perform Service Campaign P29 to limit Max Charge to 80% before
releasing back the vehicle to the customer, if it has not already been performed. If P29 was already performed,
make sure it is still set at 80% Max Charge. Note that the customer will not receive a second $200 gift card if one
has already been issued for P29.
• Vehicles that have GDS result of “BMS Update” can complete the Recall 200 only with a BMS Update and setting the %
Max Charge back to 100% per the flowchart of page 2 of TSB 21-01-046H-2. Please read the information below with
background information regarding Recall 200 to help you provide the best customer experience.
Please note that Service Campaign P29 remains the interim step for vehicles that are awaiting, or have not completed, the
repair for Recall 200. DO NOT complete P29 after Recall 200 repair is performed.
The Issue
The subject vehicles are equipped with battery cells manufactured in the LG Energy Solutions China (Nanjing) plant in which the Anode
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Page 3 of 25
(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. An electrical short internally within battery cell(s) increases the risk of a vehicle fire while
parked, charging and/or driving.
Hyundai previously issued Recall 196 for Kona EV which provided Hyundai dealers the ability to update software and inspect the
lithium-ion battery and replace if necessary. Customers who completed Recall 196 and have Recall 200 open still need to
complete the entire Recall 200 TSB. Recall 196 is not a substitute for Recall 200.
Customers will receive a final notification letter with remedy available. The Battery System Assembly (BSA) will be inspected and
replaced if necessary and a BMS software update may also be required. If the Malfunction Indicator Light is illuminated in their vehicle,
they should seek service at a Hyundai dealer as soon as possible.
Interim Solution (Service Campaign P29)
Service Campaign P29 should continue to be completed on all affected vehicles until the remedy procedures can be
performed for Recall 200.
Customers should park and charge outside and away from structures until they can reduce their vehicle’s ‘Max charge %’ level
to 80% as described below.
In an effort to maintain high customer satisfaction, Hyundai is doing the following:
• Providing an interim solution that limits the electric battery’s state of charge capacity to 80%. This can be easily done by
adjusting the settings in the navigation head unit.
o By adjusting the capacity, it can reduce the risk of a vehicle fire caused by the lithium-ion battery.
o This can be performed by the dealer or at the convenience of the customer at their home.
o Please refer to TSB# 21-01-027H for step-by-step instructions on how to adjust these settings.
• Hyundai is providing a one-time $200 gift card to customers who adjust these settings in the interim, as verified by their local
dealer, to compensate them for the inconvenience of reduced mileage range. Refer to TSB# 21-01-027H.
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Page 4 of 25
Recall 200 Flowchart
For all 2019-2020MY vehicles with an open Recall 200, follow TSB 21-01-046H-2 flow chart below. It can also be found on pages 2-3 of
the TSB.
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To wa1ch video of the TSB procedure, scan QR code or open: https://V imeo.com/597455357/a559bdea14 II
TSS 21-01-046H- l 2019-2020MYKONA EV RECALL 200 PROCEDURE SUMMARY: (2 pas es)
Vehldeln
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Page 5 of 25
EV Battery Handling
Ensure the team is ready to receive the EV batteries that are arriving at the dealership. Ensure that all safety and precaution steps are
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37501-K.K.lf 1<.XUQH BSA pa rt wa 5 a I ready inst.a 11 ed In past [cheek battery la he ll ordieckwith Te chllne If case Is stl II In process end BSAWlllslilpla er. Perform BMS U,pd 11te #707 11~er It Is confirmed that 11n AS or QQH ,BSA i! installed in the vehicle, J NOTE: AJso refer to TSB 21~EE-002H·l for BSA dehiled EV B~tuy Approv.l Prowu H;;mdling ,1nd Repl,1c:ermmt Proc;11dw115. PA Approved -to R!!pl11c!! BSA • NON-INCIDENT VEHICl£: Rele,1se after setting vehicle AVN Max % Charge 5etting to 80% (claim P29 campaign if open1 • Schedule biick to re~ce BSA when tools ;md parts on hand. • INa0ENT VEHICLE jEV light On ;1nd OTC P1AA61; Hold vehide and place rustomer- in alternative transportation, + .. Perform BMS !,CJ.I Upd.a te ln07 NOTE; Return tll~ 11 erl 11.lttery ro.-e pe, TSB 2.1-EE-OO.JH Page 6 of 25 followed each time the EV battery arrives. See below for a high-level summary of the process. For details of the EV Battery Handling Process for Recall 200, please CLICK HERE. 1. Parts Information and Parts Ordering o Contact Warranty PA prior to ordering an EV Battery (BSA) for Recall 200. Dealer can order BSA and associated parts for Recall 200 only after PA approval. Note: For Recall 196 or Campaign T5V, please contact Techline should those TSBs require BSA replacement. o Place parts order for EV Battery and associated parts after PA Approval through HyundaiDealer.com/Parts>WebDCS> Order Entry. Follow the normal CSP ordering process (VIN and PA Approval
are required).
2. Receiving and Handling of EV Battery at the Dealership
o Receiving: The delivery truck driver is responsible for removing the battery container by pallet jack from the delivery
truck using its lift gate. If the dealership does have a forklift available, that is an alternative method to remove the
battery from the truck.
▪ Check equipment used to move the EV Battery.
▪ Inspect the battery packaging to ensure it has not been damaged in a manner that could have caused harm
to the battery.
o Handling: EV Dealer is responsible for moving the battery container from the delivery truck drop point over to a
holding area in the shop.
▪ A holding area of 45 square feet is needed for each EV Battery container.
▪ Handle EV Batteries with caution and safety to avoid damage.
3. Storing and Stacking EV Battery
o Store the battery container under a covered storage area if possible.
o Battery containers may be stacked 2-3 high assuming there is no structural metal frame damage to the battery
containers as received and is in its original container.
o Keep original packaging for repurpose to return a used EV battery for proper recycling.
4. Used EV Battery Return
o Follow the TSB as noted below for information on how to return a Recall 200 replaced battery for proper disposal and
safe environmental recycling using Hyundai’s authorized vendor.
▪ TSB 21-EE-003H: RECALL 200 KONA EV BATTERY RETURN
o IMPORTANT: Hazmat Shipping Certification Regulation
▪ Per strict Hazmat shipping regulations, you must accurately declare whether your facility personnel handling
the battery shipment has been certified by an approved Hazmat shipping training program.
▪ If your facility’s personnel does not have the proper certification, please proceed to www.HazMatU.org to
sign up and complete the hazardous materials training prior to submitting a request to pick up the used EV
Battery.
5. Submitting a return/claim for a Damaged EV Battery
o Verify and complete Hazardous materials training
o Submit damaged DCD claims in a timely manner with through documentation and photos of the damage.
Please review the detailed instructions HERE.
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Customer Talk Tracks
The following talk tracks can help you navigate a difficult conversation with any customer affected by this recall. Please use
the appropriate talk track based on the type of customer interaction.
Scenarios
Dealer
Actions
Customer Talk Tracks
In-Person Over-the-Phone
Vehicle Has Recall 200
Dealer Has Tools
Required/Training Completed
All Customers
requesting
information on
Recall 200
Make sure to check
WebDCS if their vehicle is
affected by the Recall 200 or
any other open campaigns.
“Hello Mr/Mrs Customer,
Thank you for coming in today for the
safety recall on your [insert vehicle
model]. First, I am going to double check
and confirm if your vehicle is affected by
this recall or if there are any other open
recalls. Also, are you experiencing any
issues with your vehicle or have any
malfunction light indicators currently on
you would like to get looked at today?”
“Hello Mr/Mrs Customer,
Thank you for contacting us about the safety recall on your [insert vehicle
model]. May I have your contact information and your vehicles VIN# to
confirm your vehicle is affected by this recall? Also, are you experiencing any
issues with your vehicle or have any malfunction light indicators currently
on?”
✅ ✅
Recall 200 is active and
dealer has tools available
and training completed.
Action: Recall 200 remedy
should be completed per the
Recall 200 flowchart
procedure.
If not, P29 should be
completed and SOC set to
80% until Recall 200 remedy
procedures can be
performed.
“I have confirmed your vehicle is affected
by this recall. Hyundai has implemented
the recall remedy for the Battery System
Assembly to be inspected and replaced if
necessary and may include a software
update.
Should the battery inspection result not
require battery replacement, then a
software update will be performed, and
the vehicle will complete the recall repair
allowing for normal charging to 100%.
Should the result of battery inspection
find the need to replace the battery, I will
set up an additional tentative future
appointment with you pending the arrival
of the parts required to get the Battery
System Assembly replaced. If the
malfunction indicator light comes on, you
should bring your vehicle back in to a
Hyundai Dealership as soon as possible.”
“In the meantime, Hyundai is
recommending parking your vehicle and
charging outside until you adjust the Max
Charge percentage level to 80%.
Adjusting this setting can be done quickly
and we can adjust this setting today. It is
important to know, by adjusting the Max
Charge percentage level to 80%, it will
reduce the mileage range of your vehicle.
Due to this inconvenience of reduction of
range, Hyundai would like to offer a onetime
$200 gift card that will be provided to
you once the reduction results have been
received. We have to plug our scan tool
into your vehicle and record the adjusted
settings. Once this is complete, Hyundai
will send a gift card to your verified email
address within 10 business days.
Can you please confirm your current
email address? I have listed ________.
This email is how we’ll send you the $200
“I have confirmed your vehicle is affected by this recall and I am happy to hear
you currently are not experiencing any issues.
We need to make an appointment for you to come in for the Battery System
Assembly to be inspected and replaced if necessary and may include a software
update.
Should the battery inspection result not require replacement, then a software
update will be performed and the vehicle will complete the recall repair allowing
for normal charging to 100%.
Should the result of the battery inspection find the battery needs to be replaced,
I will then need to set up a tentative future appointment with you pending the
arrival of the battery to get the Battery System Assembly replaced and update
the software. If the malfunction indicator light comes on, you should bring your
vehicle in to a Hyundai Dealership as soon as possible.”
“In the meantime, Hyundai is recommending parking your vehicle and charging
outside until you adjust the Max Charge percentage level to 80%. Adjusting this
setting can be done quickly on your vehicle’s infotainment system. We can
adjust this setting for you at our dealership or I can send you step by step
instructions to your email, so you can do it from the convenience of your home. It
is important to know, by adjusting the Max Charge percentage level to 80%, it
will reduce the mileage range of your vehicle. Due to this inconvenience of
reduction of range, Hyundai would like to offer a one-time $200 gift card that will
be provided to you once the reduction has been verified at the dealership. We
will have to plug in our scan tool to your vehicle and record the adjusted
settings. Once this is complete, Hyundai will send a gift card to your verified
email address within 10 business days.”
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Page 8 of 25
Scenarios
Dealer
Actions
Customer Talk Tracks
In-Person Over-the-Phone
Vehicle Has Recall 200
Dealer Has Tools
Required/Training Completed
gift card, and we want to make sure you
receive it!”
✅ ❌
Recall 200 is active but
Dealer does not have tools
available and training
completed.
Action: Perform Recall 200
GDS battery inspection to
determine whether the BSA
must be replaced. If GDS
result is “BMS Update”
complete the Recall remedy
per the Recall 200 flowchart.
If GDS result is “Replace
BSA”: Complete P29 on the
customer’s vehicle and set
SOC to 80%. Set up a
tentative appointment, at
least 1 month out, with the
customer to complete Recall
200. Follow the Special
Tools section in TSB 21-EE-
002H-1, or latest, to
complete the Special Tools
Acknowledgment Form and
email
[email protected]
and/or complete the Electric
Vehicle Battery R&I Training
WBT on HLP.
“I have confirmed your vehicle is affected
by this recall. Hyundai has implemented
the recall remedy for the Battery System
Assembly to be inspected and replaced if
necessary and may include a software
update.
Should the battery inspection result not
require battery replacement, then a
software update will be performed and
the vehicle will complete the recall repair
allowing for normal charging to 100%.
Should the result of battery inspection
find the need to replace the battery, I will
set up an additional tentative future
appointment with you pending the arrival
of the necessary tools and parts required
to get the Battery System Assembly
replaced. If the malfunction indicator light
comes on, you should bring your vehicle
back in to a Hyundai Dealership as soon
as possible.”
“In the meantime, Hyundai is
recommending parking your vehicle and
charging outside until you adjust the Max
Charge percentage level to 80%.
Adjusting this setting can be done quickly
and we can adjust this setting today. It is
important to know, by adjusting the Max
Charge percentage level to 80%, it will
reduce the mileage range of your vehicle.
Due to this inconvenience of reduction of
range, Hyundai would like to offer a onetime
$200 gift card that will be provided to
you once the reduction results have been
received. We have to plug our scan tool
into your vehicle and record the adjusted
settings. Once this is complete, Hyundai
will send a gift card to your verified email
address within 10 business days.
Can you please confirm your current
email address? I have listed ________.
This email is how we’ll send you the $200
gift card, and we want to make sure you
receive it!”
“I have confirmed your vehicle is affected by this recall and I am happy to
hear you currently are not experiencing any issues.
We need to make an appointment for you to come in for the Battery System
Assembly to be inspected and replaced if necessary and may include a
software update.
Should the battery inspection result not require replacement, then a software
update will be performed and the vehicle will complete the recall repair
allowing for normal charging to 100%.
Should the result of the battery inspection find the battery needs to be
replaced, I will then need to set up a tentative future appointment with you
pending the arrival of the necessary tools and battery to get the Battery
System Assembly replaced and update the software. If the malfunction
indicator light comes on, you should bring your vehicle in to a Hyundai
Dealership as soon as possible.”
“In the meantime, Hyundai is recommending parking your vehicle and
charging outside until you adjust the Max Charge percentage level to 80%.
Adjusting this setting can be done quickly on your vehicle’s infotainment
system. We can adjust this setting for you at our dealership or I can send
you step by step instructions to your email, so you can do it from the
convenience of your home. It is important to know, by adjusting the Max
Charge percentage level to 80%, it will reduce the mileage range of your
vehicle. Due to this inconvenience of reduction of range, Hyundai would like
to offer a one-time $200 gift card that will be provided to you once the
reduction has been verified at the dealership. We will have to plug in our
scan tool to your vehicle and record the adjusted settings. Once this is
complete, Hyundai will send a gift card to your verified email address within
10 business days.”
“Can I schedule an appointment for you today to bring in your vehicle?”
“Also, if you like, I can email you the step-by-step instructions provide by
Hyundai?” *Instructions you can copy and paste can be found on page 8.
“We apologize for the inconvenience and if you require further assistance
you may contact Hyundai Customer Care at 1-855-371-9460”
❌ – –
Recall 200 is not active.
Action: Complete any other
recalls/campaigns as
needed or other services
requested by the customer.
“Great News! After looking up your vehicle’s information, I have confirmed your vehicle does not require the recall and no
further action is required. There is no need to bring it in to the dealership and you should have no issues. If you need
assistance with any current service needs or would like to schedule your next service visit, I would be happy to assist!”
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Page 9 of 25
Recall 196 & 200 Overlap Vehicles Customer Talk-Tracks
The Issue
As an alternative temporary solution to the battery shortage, Hyundai previously issued Recall 196 to reduce the maximum charging
capacity to 80% to help with the prevention of potential fire risks. Some of these vehicles did not receive a replacement Battery System
Assembly under Recall 196. Some of these vehicles came in for 200 and only had the software updated. These vehicles require the
Battery System Assembly to be replaced because nearly all 19 model year vehicles in Recall 200 require the Battery System Assembly to
be replaced. Some 2020MY vehicles may require battery replacement depending upon the inspection procedure via the GDS.
Customer Handling
Dealers need to call these customers so they come back in to complete the entire Recall 200 TSB, including Battery System Assembly
replacement, if necessary. Talk tracks are provided below to help address common customer questions and concerns. HMA will also mail
out customer notifications to encourage these customers to return.
Dealer Actions
Make sure to check on WebDCS if their vehicle is affected by the recall or any other open campaigns.
Talk Tracks
Scenario and
Dealer Actions
Customer Talk Tracks
In-Person Over-the-Phone
Dealer. Generate
Uncompleted Campaign
list for Recall 200 in
WebDCS . Use list to call
customers and invite them
in for Recall 200
completion.
NOTE: Report should be
generated for Retailed
units.
“Hello Mr/Mrs Customer,
Thank you for coming in today for the safety recall on your [insert vehicle
model]. Confirmed your vehicle is affected by Recall 200. Also, are you
experiencing any issues with your vehicle or have any malfunction light
indicators currently on?”
“I will add this Recall 200 to your repair order today as well. This recall will
possibly take 2-3 days to complete. Will you be needing alternative
transportation?”
“Hello Mr/Mrs Customer,
Good morning or good afternoon. I am contacting you regarding safety
Recall 200 on your [insert vehicle model]. As you recall, Hyundai
developed an interim repair (Recall 196) to temporarily address the
Battery System Assembly in your car while a permanent repair was being
developed. I have confirmed that your vehicle is eligible for Recall 200.
Are you currently experiencing any issues with your vehicle or have any
malfunction light indicators on?”
“I would like to schedule your vehicle to have Recall 200 completed. This
recall will possibly take 2-3 days to complete. Will you be needing
alternative transportation?”
“What day and time works best to drop off your vehicle?”
Customer has had Recall
196 Completed
“I have confirmed your vehicle has had Recall 196 completed. Recall 196
served as a preventative interim solution while working toward a permanent
remedy. Hyundai has decided to replace the Battery System Assembly on
certain affected vehicles. Hyundai has implemented the Recall 200 for the
Battery System Assembly to be inspected and replaced if necessary, plus a
software update will be performed.
“Can I schedule an appointment for you today to bring in your vehicle?”
“I have confirmed your vehicle has had Recall 196 completed. Recall 196
served as a preventative interim solution while working toward a permanent
remedy. Hyundai has decided to inspect and replace the Battery System
Assembly on certain affected vehicles. Hyundai has implemented the Recall
200 for the Battery System Assembly to be inspected and replaced if
necessary, plus a software update may also be performed.”
“Can I schedule an appointment for you today to bring in your vehicle?”
“We apologize for the inconvenience and if you require further assistance
you may contact Hyundai Customer Care at 1-855-371-9460”
Customer response: “If
Recall 196 was completed
why do I need to come
back for Recall 200?”
“Recall 196 was an interim repair provided to help reduce the potential risk
of fire. Recall 196 involve a software change reducing the maximum
charging capacity of the battery to 80%. Completion of Recall 200 will allow
the maximum charging capacity to be set at 100%. This will prevent any
failures and extend the range in between charging cycles.”
“Recall 196 was an interim repair provided to help reduce the potential
risk of fire. Recall 196 involve a software change reducing the maximum
charging capacity of the battery to 80%. Completion of Recall 200 will
allow the maximum charging capacity to be set at 100%. This will prevent
any failures and extend the range in between charging cycles.”
Customer response:
“Does this mean my car
was not repaired right the
first time?””
“No, not at all. Hyundai developed a temporary solution while a permanent
remedy was being developed. The software enhancement helped with
reducing the risk of fire while allowing the vehicles to be safely operated.”
“No, not at all. Hyundai developed a temporary solution while a
permanent remedy was being developed. The software enhancement
helped with reducing the risk of fire while allowing the vehicles to be
safely operated.”
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Page 10 of 25
Scenario and
Dealer Actions
Customer Talk Tracks
In-Person Over-the-Phone
Customer response: “I
thought Recall 200 was
already completed. Why
do I need to come back?”
“While the repairs for Recall 200 were in development Hyundai proactively
implemented Recall 196 to ensure customers can safely operate their
vehicles. Further, it helped identify vehicles requiring the Battery System
Assemblies once they were available.”
“While the repairs for Recall 200 were in development Hyundai
proactively implemented Recall 196 to ensure customers can safely
operate their vehicles. Further, it helped identify vehicles requiring the
Battery System Assemblies once they were available.”
Setting Max Charge Instructions for Service Campaign P29
Instructions you can copy and paste into email to send to customer
• Adjust or confirm your vehicle’s ‘Max charge %’ level to 80%. This can be done manually at home using the
infotainment system with these steps:
o Turn the vehicle ignition ON without starting the engine.
o Depending on radio select: EV on display screen (7 in) or battery display (10.25 in)
o Select Energy Information.
o Select DC Charger.
o Press the Minus (-) Sign until the charger percentage reaches 80%.
o Select OK when complete.
o Perform the same steps once more for the AC Charger.
o Both the DC and AC charge percentage will now be set and displayed at 80%.
o See instructional video www.youtube.com/watch?v=dk-FrxW5bRM
• If your vehicle is currently subscribed to Bluelink, Hyundai will attempt to remotely set your ‘Max Charge %’ to 80% within the
next week. You can verify the setting following the steps above.
• You must go to the dealership to verify or adjust ‘Max battery %’ level reduced to 80%. Once verified at the
dealership you will receive a one-time $200 gift card due to the inconvenience of reduction of range. Please
provide the dealer with a valid email address and allow 10 business days for processing.
• If you cannot adjust or go to the dealership to achieve ‘Max charge %’ level to 80%, park and charge your
vehicle outside and/or away from structures until the ‘Max battery %’ level has been reduced to 80%.
Service Actions
Reservation – Always check the Vehicle Information Screen in WebDCS for open campaigns and recalls and advise
the customer on time requirements.
• Use talk tracks above before scheduling an appointment for this recall
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.
• Please read the above description and talk tracks prior to discussing this recall with the customer.
• Be prepared to hold the vehicle and put customers in an SRC or alternative transportation, if needed.
:l)RfAOINUS 4JREPAIR l)lt.ECONNECT
V~ Hyundai ~ Assurance Car Core ,.. ,..
Y)RECEPTION llltrTURN
Page 11 of 25
• Technician Training Recommendation:
Expert Certified and has completed EV Safety, 2019 Kona EV new model course, and the EV Battery R&I course.
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.
• Use the talk tracks above before performing any repairs.
• Confirm the customer’s current email address that they want the one-time $200 gift card sent to after completion of
P29, if needed. The Customer Connect team will use the email address listed on the RO from the Campaign Claim to
distribute the gift card.
Repair – Always plug in the GDS before starting the repair. Make sure to complete an MPI on all vehicles and Quality
Control your work.
• Reviews the procedures for Recall 200 on the TSB.
• NOTE: Once Recall 200 is fully completed, P29 (if open) does not need to be completed.
• IMPORTANT:
• Refer to TSB 21-EE-002H-1 for EV Battery Approval, Handling, and Replacement Procedures.
• Parts CSP order of a replacement BSA requires Warranty PA approval and VIN.
• Dealer Tools and Tech Training requirements must be satisfied for PA approval.
• Review the Service Procedure Summary Chart on Page 2 of the TSB 21-01-046H-2.
• An Incident Vehicle received with EV Warning light on and DTC P1AA600 found stored in the BMS must have the
BSA replaced. Contact Techline if the BSA had already been replaced in the past for a DTC P1AA600.The following
photos are required to be submitted to HMA via GDS STUI camera upload of the Battery System Assembly label (see
TSB 21-01-046H-2 for more details):
• Original Battery Label in vehicle as received
• Replacement Battery Label
• Non-Incident Vehicle: If the vehicle will be driven while waiting for the EV battery shipment, ensure the vehicle
has been set at 80% Battery SOC prior to release of the vehicle back to the customer.
• For ECU Update: The manual upgrade should only be performed if the automatic upgrade is unsuccessful.
• If automatic upgrade is unsuccessful, turn the ignition key off for about 10 seconds, then place it back to
the on position to reset the control unit before performing manual upgrade.
• Please refer to details for EV Battery Handling Process for Recall 200 HERE.
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.
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IP:S;.-,
~
Page 12 of 25
Warranty
Parts
• Battery System Assembly replacement must have Warranty PA approval prior to ordering and replacing the BSA.
• NOTE: Confirm the color of the coolant in the subject vehicle. Do not mix colors of coolant.
• Please refer to details for EV Battery Handling Process for Recall 200 HERE.
Hyundai
Assurance Car Core
~ T
JOREC[PTION IIR£TURH
Model Op Code Operation Op nme causal Part Nature cause
11D043R2 BAR CODE READING AND BMS UPDATE 0.5M/H 375A0-K4000
BAR CODE READING AND
11D043R3 BSA REPLACEMENT 3.8 M/H 37501-K4000AS
(Parts ending in ‘AS” used)
BAR CODE READING, BMS
11D043R4 UPDATE AND BSA 4.1 M/H 37501-K4000AS REPLACEMENT
(Parts ending in ‘AS” used)
BAR CODE READING AND
Kena Electric
11D043R6 BSA REPLACEMENT 3.8M/H 37501-K4000RW
(OSEV) (Parts ending in “RW’ used) D22 ZZ3
BAR CODE READING, BMS
11D043R7 UPDATE AND BSA 4.1 M/H 37501-K4000RW REPLACEMENT
(Parts ending in “RW’ used)
BAR CODE READING AND
11D043R8 BSA REPLACEMENT 3.8M/H 37501-K4000RA
(Parts en ding in ‘RA” used)
BAR CODE READING, BMS
11D043R9 UPDATE AND BSA 4.1 M/H 37501-K4000RA REPLACEMENT
(Parts ending in ‘RA” used)
NOTE 1: Additional reimbursement of 0.3 MIi-i has been included for 11D043R3-1 1D043R9 claims for
unpackaging/handling/repacking lhe EV battery per procedure of TSB 21-EE–0021-1-1, and Max Charge %SOC
adjuslmenl to 80% if needed to interim release a non~ncident vehicle prior to parts arrival. If Service Campaign P29 is
also open on the vehicle, please ensure a campaign claim is also submitted for P29 to dose it.
NOTE 2: Submit Claim on Campaign Claim Entry Screen.
NOTE 3: If a pan not covered by this campaign is found in need of replacement while performing this Recall Ca~ign
and the affected part is st~I 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 perfoming the
work.
NOTE 4: Failure to include the necessary original and replacement battery labels in STUI according lo the flowchart on
pages 2-3 will result in delay of claim payment.
and rep acing e . rder CSP with VIN an a er pprova .
NOTE: Enter PIN order endm with AS, however the
37501-K4000AS 2019MY Battery System Assembly
(BSA)
37501-K4001 AS
37501-K4051AS
00232-19010
00232-19091
37535-Gl50000H
37535-0405000H
Battery System Assem
(BSA)
Unheated Batte
2020MY Battery System Assembly
(BSA)
Vehicle
built
before
517119.
Vehicle
built
517119
or later.
2019-
2020MY
(Heated Battery)
Green Coolant
(standard coolant)
Blue Coolant
(IOW conductivity type)
Bolt & Washer Assembly
rsede it to end in RW or RA.
1 qty.
x4L
bottle
3 qty.
x 2L
Bottle
18
4
All 2019MY
lden~fy the
correct
20MYBattery
from the
vehicle’s
Battery Label,
but add AS to
end of the PIN.
Mix 50/50
with water.
Do not mix
with water.
Must replace
and discard
the Old bolts.
Page 13 of 25
EV Battery Special Tools Information:
• The following special tools are required for the safe, secure, efficient lifting of large heavy EV
battery (~1000lbs). Proper tools are required to avoid damage to the EV battery.
• The tools listed below will be ordered from Bosch by Hyundai on receipt of the Tool
Acknowledgment Form of the next page when indicating need.
• Bosch, at the permission of Hyundai, may contact dealer to substitute alternative tools for dealer
orders when there is supply issue.
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JOREC[PTION IIR£TURH
PART NAME/
(Part Number) DIAGRAM REMARK
PREFERRED TOOL*
Propulsion System
Lift Table
(PIN: HMA52200-A)
• f or Recall 196/200
alternative tables rated fo
at least 11 00lbs and
min imum table size o
20″‘x 36″ are being
c onsidered for temporary
use. Complete the ”Tool
Acknowledgment Form·•
onne~pageandsend
for approval by email to:
HyundaiTools@hmausa
.com
REQUIRED TOOL
High Voltage Battery
Lifting Fixture
(PIN: 09375-K4100)
20MY~ AE EV only
High Voltage Battery
Pack. Transport Hanger
(P/N: 09375-G7100}
ifii
/Ill
Allows for safe and efficient EV
batteiy replacement
Engine hoist can lit under it to
,aise an EV battery from the table.
Multi-Use air/hydraulic operated
lift rated at 1760 lbs. capacity can
lift21_5 to 70 inches high.
Multiple uses include EV Battery,
Engineffransaxle, Fuel Tank,
Cradles, Suspensions, and
Chassis systems_
Fits All Hyundai
EV Battery_
NOTE:
dditional tool to complement
the above Lifting Fixture
but only applies for
20MY and later
loniq AE EV that
uses coolant.
Page 14 of 25
NOTE: The following page must be completed when PA or Techline does not have record of your Dealership having
approved EV battery tools. Service Manager completes this form and sends it by email to: [email protected]
Dealer completes the form only once, not for every EV Battery Replacement.
EV Battery Replacement Special Tools Acknowledgment Form
EV battery replacement requires a special lift table and a high voltage battery lifting fixture(s) to safely remove and replace large
heavy EV batteries. 20MY~ Ioniq AE EV requires an additional hangar.
For your first EV battery order, the following essential tools will be shipped to your dealership and billed through the Bosch Special
Service Tool program, unless otherwise noted in bottom section:
• Propulsion System Lift Table (P/N: HMA52200-A)
• High Voltage Battery Lifting Fixture (P/N: 09375-K4100)
• High Voltage Battery Pack Transport Hanger (P/N: 09375-G7100) will only be shipped for 20MY~ Ioniq AE EV Water
Cooling Type battery.
Check here if your dealership needs both the Lifting Fixture and Lift Table tools: ____
The undersigned acknowledges receipt of this notice and understands that the dealer will be billed for these tools when needed for
an initial order of an EV battery with exception of a lift table when an alternative is approved as indicated in the below section.
Dealer Name: ___________________________________
Dealer Code: ____________
VIN: ____________________________________________
Dealer Service Manager:
Print Name: _____________________________________________
Signature: ______________________________________
If your Dealership already has access to an equivalent compatible lift table suitable for EV batteries, then complete this
section to seek HMA approval of your alternative lift table.
Please check mark the following to select the tools your dealership already has:
• Propulsion System Lift Table / Brand: ______________ Model Number: __________________
• High Voltage Battery Lifting Fixture (P/N: 09375-K4100)
• 20MY~ Ioniq (AE EV) High Voltage Battery Pack Transport Hanger (P/N: 09375-G7100)
I certify the above-mentioned dealer has the above indicated tools to consider for Hyundai EV models.
Manager, District Parts & Service:
Print Name: ____________________________________
Signature: _____________________________________
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Page 15 of 25
Customer Notification
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.
Thank you for your prompt attention to this important matter and continued commitment to Hyundai customers.
Hyundai Motor America
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Page 16 of 25
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.
Q10: What is the difference between an incident and a non-incident vehicle? What should dealers do if a battery replacement is
required for an incident & a non-incident vehicle?
A10: An incident vehicle is when a vehicle has the DTC P1AA6 and the EV Warning Light ON. A non-incident vehicle does not have
these two items. If a battery replacement is required for an incident vehicle, vehicle must be held and customer placed in alternative
transportation. If a battery replacement is required for a non-incident vehicle, vehicle may be released to the customer after the Max %
Charge setting (SOC) is set to 80%. Dealer should then schedule customer in to the dealer to pick up vehicle once dealer has replaced
the battery with the necessary tools/parts on-hand.
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Page 17 of 25
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 [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
(GeneralQuestions)
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
NHTSAWebsite www.safercar.gov
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Page 18 of 25
Appendix
Updates to This Document Date
• Once Recall 200 has been completed, set the vehicle Max Charge back to 100% 11/18/21
• Recall 200 Remedy – (TSB# 21-01-046H-1): Adding 20MY vehicles with Remedy Available
• Removal of notations to ‘200X’ for Recall 200
• EV Special Service Tool requirements (pg. 13)
• Revised service procedure/workflow (pg. 4)
• Updated Customer Talk Tracks for Recall 196/200 customers that have not had their EV Battery System
Assembly replaced (pg. 7)
• If vehicle requires a battery replacement and vehicle does not have P1AA6/EV Warning Light ON (non-incident
vehicle), please set SOC to 80% and then submit a P29 claim if still open on the vehicle.
09/10/21
• Recall 200 Remedy Now Available (TSB# 21-01-046H) for 2019MY Kona Electric (OS EV)
• 2020MY Kona Electric (OS EV) and 2020MY Ioniq Electric (AE EV) – REMEDY NOT YET AVAILABLE –
Proceed with Campaign P29 in the interim
• Interim Step to Recall 200, Service Campaign P229, remains in effect for vehicles that are awaiting, or have not
completed, the repair for Recall 200.
06/10/21
Key Note in Repair ‘Section’: All related open campaigns 196, T5V, and T6C, if applicable, must be completed
prior to completing campaign P29.
04/01/21
P29 Dealer Best Practice Launched – Interim Step to Recall 200
• Table of contents, customer handling section, talk tracks and more added!
• P29 is the Interim Step to Recall 200 – Adjust SOC to 80% for affected vehicles that come in
• Information about $200 gift card
03/31/21
• Remedy not available 03/05/21
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Page 19 of 25
TSB No. Ref: TSB: 21-01-046H-1
Model: Certain 2019 & 2020 MY Kona Electric (OS EV) vehicles
Date: September 10, 2021 P/N: Refer to TSB: 21-01-046H-2
BATTERY MANAGEMENT SYSTEM SOFTWARE UPDATE AND
BATTERY SYSTEM ASSEMBLY REPLACEMENT (RECALL 200)
Detailed EV Battery Parts Procedures for Recall 200
▪
▪
V~ Hyundai Assurance Car Core
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JOREC[PTION IIR£TURH
<B)HYUnDRI Parts Bulletin
I
1. Parts Information and Parts Ordering
Review the following TSBs prior to ordering an Recall 200 EV Battery:
TSB: 21-01-046H-1: BATTERY MANAGEMENT SYSTEM SOFTWARE UPDATE AND BATTERY
SYSTEM ASSEMBLY REPLACEMENT (RECALL 200)
Part Information
Part Number Year Description Photo Quantity Remarks
NOTE: Battery System Assembly (BSA) replacement must have Warranty PA approval prior to
orderin and re lacin the BSA. Order CSP with VIN and after PA A roval.
37501 -K4000AS 2019MY Battery SyStem Assemb:ly All 2019MY
{BSA)
Battery System Assemb:ly
37501-K4001AS {BSA)
(Unheated Battery)
1———-< 2020MY 1———–1 Battery System Assemb:ly 37501-K4051AS {BSA) (Heated Battery) 1 —— Identify the correct 20MY BatteIY from the vehicle’s Battery Lane/, but add AS to end of PIN. NOTE: Technician should confirm color of coolant in the sub·ect vehicle. Do not mix coolant colors. 00232-19010 00232-19091 37535-Gl500QQH 37535-Q4050QQH Vehide built before 5f7/19. Vehide built Sll/19 or later. 2019- 2020MY Green Coolant {standard coolant) Blue Coolant {low conductivity type) Bolt & Washer Assembly J ,..,. 1 qty. X 4L bottle 3 qty. X 2L Bottle 18 4 Mix 50/50 with water. Do not mix with water. Must replace and discard the old bolts. TSB 21 -EE-002H-1: ELECTRIC VEHICLE (EV) BATTERY APPROVAL RECEIVING AND REPLACEMENT PROCEDURES Page 20 of 25 ▪ ▪ ▪ V~ Hyundai Assurance Car Core ~ T JOREC[PTION IIR£TURH Action ltem(s): Contact Warranty PA prior to ordering an EV Battery for Recall 200. Dealer can order EV Battery and associated parts for Recall 200 only after PA approval. Note: For Recall 196 or Campaign TSV, please contact Techline prior to ordering EV Battery Place parts order for EV Battery and associated parts after PA Approval through HyundaiDealer.com/Parts>WebDCS> Order Entry. Follow the normal CSP ordering process
(VIN and PA Approval are required).
2. Receiving and Handling of EV Battery at the Dealership
The delivery truck driver is responsible for removing the battery container by pallet jack from the
delivery truck using its lift gate.
If the dealership does have a forklift available, that is an alternative method to remove the battery
from the truck.
Action ltem(s):
Check equipment used to move the EV Battery. Verify and inspect that all equipment
required for moving EV Battery are available and in working condition.
Logistics equipment specifications(handling BSA)
m
.c r
C 0
-· 10
“O – · 3 ~
I::D::, n- ·
,+
Equipment
Fo rk-Li ft
Characteristic
■ Place of use: in/outbound area, Floor
■ Equipment Specifications
– Electric(2.5t), Diesel(3. St)
@Fork:
– Length : more than 1800mm/70.87 inc hes
– Width : less than 130mm / 5.12 inches
– Thickness: less than 90mm / 3.54 inches
L Based on the thickest part of the fork)
■ Place of use: Floor/Shelf rack area
■ Equipment Specifications
– Electric(1 .8t, 2.0t , 2.St)
Remarks
The fork must be
long and wide
enough to
withstand the
weight of item.
The thickness must
@ Fork : be thinner the fork
– Length : more than 1800mm/ 70.87 inches tube(100mm).
– Width : less th an 130mm / 5.12 inches
– Thickness: less than 90mm / 3.54 inches
L Based on the thickest part of the fork)
Page 21 of 25
▪
▪
▪
▪
V~ Hyundai Assurance Car Core
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JOREC[PTION IIR£TURH
Inspect the battery packaging to ensure it has not been damaged in a manner that could
have caused harm to the battery.
Receiving and Inspecting of EV Battery upon Delivery
m <
OJ
Q) :::::
Cl)
‘<
0
Cl)
<” Cl)
‘< Examples Details ■ Example of a battery container received in good condition ■ It is possible some cardboard may rip away during transportation and handling, this is OK so long as there is no evidence that something protruded in to make contact with the battery NOTE: In event of any significant damage that may have compromised the battery, halt delivery and do not sign receiving document until you have taken arrival photos. Indicate damages onto the receiving document and take delivery, store battery container outside and file an MPA dealer return claim. Action ltem(s): File any EV Battery claim (Damage, Shortage, Wrong Part, etc.) through Hyundai Dealer.com >Parts>WebDCS. Follow the normal return/claim process.
For new Damaged EV batteries, Carrier inspection will occur at the Dealer prior to returning
the damaged battery.
Schedule an EV Battery Pickup Request via the EV Battery Return Portal:
Hyundaidealer.com >Parts> Recall 200 EV Battery Return
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EV Dealer is responsible for moving the battery container from the delivery truck drop point over to
a holding area in the shop.
Action ltem(s):
Verify capacity is sufficient for storing EV Batteries. A holding area of 45 square feet is needed
for each EV Battery container.
Handle EV Batteries with caution and safety to avoid damage.
EV Battery Handling precautions
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Examples
3. Storing and Stacking EV Battery
Details
■ Please handle just one battery at a time.
– The center of gravity is shifted to one side
because of the weight biased shape.
-Handling a multi level of parts poses a
safety risk due to the dang er of weight
bias.
■ Handle the forklift by pushing the fork all
the way to the innermost part of the pallet
– Especially, when forking in the
longitudinal direction, the heavy side
should come toward the machine.
Store EV Batteries safely inside the facility. In the event it is not possible to store the battery
container inside due to facility constraint:
Store the battery container under a covered storage area if possible.
If it mustbe left in an exposed area, avoid constant high sun exposure areas.
Cover the battery container with a waterproof tarp secured in place to protect the battery
from being exposed to the elements.
Battery containers may be stacked 2-3 high assuming there is no structural metal frame damage to
the battery containers as received.
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Action ltem(s):
Verify EV Battery is not stored under direct sunlight.
Do not store EV Battery near water or conductive materials.
EV Batteries should not be stacked if it is not in the original battery containers.
Do not dispose of the packaging that the EV battery was shipped in. Packaging should be
retained and repurposed to return a used EV battery for proper recycling.
EV Battery storage precautions (Floor)
Examples
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4. Used EV Battery Return
WRONG
HEAVY
HEAVY
HEAVY
Exarrple of stacking
Details
■ Stacking
– Stack in 3 or less
– St ack only with same part
packed with same package material
– Load by aligning the slot of pallets
■ Stack up by c hanging directions
– Weight biased risk due to battery shape
– Stack up boxes with weight balance
(Change the direction of the boxes
stacking up) * It is weight biased toward the side
with the HEAVY label attached
Follow the TSB as noted below for information on how to return a Hyundai EV Battery for proper
disposal and safe environmental recycling using Hyundai’s authorized vendor.
TSB 21-EE-003H: RECALL 200 KONA EV BATTERY RETURN
IMPORTANT: Hazmat Shipping Certification Regulation
Per strict Hazmat shipping regulations, you must accurately declare whether or not your
facility personnel handling the battery shipment has been certified by an approved Hazmat
shipping training program.
If your facility’s personnel does not have the proper certification, please proceed to
www.HazMatU.org to sign up and complete the hazardous materials t raining prior to
submitting a request to pick up the used EV Battery.
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Action ltem(s):
Verify and complete the Hazardous materials training.
Schedule an EV Battery Pickup Request via the EV Battery Return Portal:
Hyundaidealer.com > Parts > Recall 200 EV Battery Return
Inspect the condition of the used EV Battery. Note any physical damages or odor. Take
photos of any damages.
Inspect EV Battery packaging in which the replacement battery was received. Indicate any
significant physical damage to the packaging when scheduling a pickup of the used EV
Battery.
Use the original packaging that the EV battery was shipped in to return a used EV battery.
5. Submitting a return/claim for a Damaged EV Battery
Create a new claim for any damaged EV Battery through HyundaiDealer.com >Parts>WebDCS.
Follow the normal Damage (DCD) claim process.
The dealership staff must be HazMat certified in order to return HazMat Parts back to the PDC.
Per strict Hazmat shipping regulations, you must accurately declare whether or not your
facility personnel handling the battery shipment has been certified by an approved Hazmat
shipping training program.
If your facility’s personnel does not have the proper certification, please proceed to
www.HazMatU.org to sign up and complete the hazardous materials training.
The disclaimer below will appear when submitting a DCD claim for HazMat Parts.
Dealer must enter personnel name at the dealership that is HazMat Certified.
Disclaimer
DOT requires the shipper of HAZARDOUS MATERIALS
to be trained and tested according to the training
requirements m CFR 49_Sect1on 172.704.
You can only return these parts if you have been tested
and certified to prepare and ship HAZARDOUS
MATERIALS according to these requirements.
Are you certified to prepare and ship HAZARDOUS
MATERIALS?
Hazmat Cenlfled Personnel Name Required:
* First Name JOHN
* Last Name [ SMITH
Acknowledgement 0l/0l/2021
Date
iiWF Gi:1@9
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)(
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Follow additional key tips below to ensure that your damaged claims are reviewed and processed
in a timely manner:
Photo documentation is required on all DCD claims. Provide several photos of the damaged
part and the external packaging that best illustrates the issue on hand.
A total of 9 photos can be uploaded with a claim.
Make sure that all photos being submitted are clear. For the pick or Case ID label, the photo
should be clear enough where all the information is legible.
Indicate in the comments the type of damage: Visible or Concealed.
Provide comments detailing the type of damage and the potential cause of the damage (i.e.,
poor packaging, poor handling, etc.)
Part Label Pick Label R Case 10 Lain-I E11:tem11I Packaging OamaiiJed Part
Action ltem(s):
Verify and complete Hazardous materials training
Submit damaged DCD claims in a timely manner with through documentation and photos of
the damage.
If you have any questions regarding this bulletin, please refer to the Mobis Parts Portal or contact
the Parts Help desk at: 1-800-545-4515.
Thank you.
HMA/MPA

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