Recall 232 – Power Relay Under Rear Seat May Cause Fire – 2017-2018 Hyundai Ioniq HEV & Ionic PHV

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June 28, 2022 NHTSA CAMPAIGN NUMBER: 22V459000

Power Relay Under Rear Seat May Cause Fire

An overheated PRA increases the risk of a fire.

 

NHTSA Campaign Number: 22V459

Manufacturer Hyundai Motor America

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 10,575

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2017-2018 Ioniq HEV and Ionic PHV vehicles previously recalled under recall number 18V-704. The Power Relay Assembly (PRA) located underneath the rear seat may overheat.

 

Remedy

Dealers will inspect and replace the main relay or PRA, as necessary, free of charge. Owner notification letters were mailed August 23, 2022. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 232. This recall replaces NHTSA recall number 18V-704. Vehicles already repaired under the previous recall will need to have the new remedy completed.

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.nhtsa.gov.

 

Check if your Hyundai has a Recall

 


Regarding Related Recall 178:

Recall 232 supersedes recall 178 as outlined below and will be deactivated. Any repairs performed in accordance with the respective 178 TSB must have a repair order (RO) open date prior to 08/11/2022. Labor operation codes applicable to the superseded recall and vehicle models will be deactivated and related claims must be submitted by 08/25/2022.

Some vehicles may not have their main relay labels visible due to a more recently installed battery pack, resulting in the PRA cover that is not removable. A PRA where the cover is not removable has the latest labels enclosed with ‘Panasonic’.

 

Description of Campaign: 

The subject vehicles may not have received the proper remedy components under Recall 178, a safety recall addressing an electrical pin fit condition on the main relays within the PRA that, if continually operated in this condition, could increase electrical resistance thereby generating heat and increasing the risk of a fire.

 

Affected Vehicles:

  • Certain 2017-18MY Hyundai Ioniq Hybrid and Ioniq Plug-in Hybrid Vehicles produced between 11/16/2016 – 08/16/2017 Ø To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS.
  • For this recall, please note that there are no new vehicles currently in dealer stock.

 

Remedy Information:

Inspect the vehicle’s existing Main Relays. If necessary, inspect the Power Relay Assembly (PRA) and replace either the Main Relays or PRA based on the PRA inspection results.

  • Estimated Repair Time: 4M/H for Main Relay Inspection, 0.9 M/H if both Main Relay/PRA inspection is required with either Main Relay or PRA replacement
  • Recommended Technician Training Level: Expert o Technician must have completed the Hybrid Vehicle Training – Classroom (SVCHHYBVEHTRN218_800) instructor led training course or equivalent.

 

Recommended Alternative Transportation: It is recommended that Service Rental Cars (SRCs) are made available for customers during the completion of this recall.

 

FAQs:  

Q1: What is the issue?

A1: The subject vehicles may not have received the proper remedy components under Recall 178, a safety recall addressing an electrical pin fit condition on the main relays within the PRA (Power Relay Assembly) that, if continually operated in this condition, could increase electrical resistance thereby generating heat and increasing the risk of a fire.

 

Q2: What is the safety concern?

A2: Increased electrical resistance between the main relay contacts could increase electrical resistance thereby generating heat and increasing the risk of a fire.  

 

Q3: Have there been any accidents or injuries?

A3: As of the date of the filing (06/27/22) to NHTSA, there are no related injuries, or reported incidents in the U.S.

 

Q4: What will be done during this recall service at the dealer?

A4: All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to have the previously applied remedy inspected and remedy components (main power relays or Power Relay Assembly (PRA)) replaced, if necessary. This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty.

 

Q5: What if the owner incurred out-of-pocket expenses for obtaining a remedy for the recall condition?

A5: Hyundai will provide owners of affected vehicles reimbursement for out-of-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 24,2022.

 

Q6: Will a Stop Sale be issued? 

A6: No, a stop sale will not be issued as there are no new vehicles in dealer inventory.  

 


23-01-024H
MARCH 2023

IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY INSPECTION / REPLACEMENT (RECALL CAMPAIGN 232)

This TSB supersedes 22-01-063H to include an information box on page 4 addressing the scenario for covered PRAs where the main relay labels are no longer visible, update the flowchart on page 5, and add Warranty notes #4 and #5 on page 3.

 

IMPORTANT

Vehicle repairs related to safety recalls are critically important and must be performed properly in accordance with TSB procedures. Review this bulletin in its entirety prior to beginning any repair work.

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.

 

Description: The subject vehicles may not have received the proper remedy components under Recall 178, a safety recall addressing an electrical pin fit condition on the main relays within the PRA that, if continually operated in this condition, could increase electrical resistance thereby generating heat and increasing the risk of a fire.

This bulletin describes the procedure to inspect the PRA and Main Relays, and replace either as defined by the service procedure flowchart.

Refer to the QR code or link below for guided video information:
https://vimeo.com/723573458/00300dddd9

 

Applicable Vehicles: Certain 2017-2018 MY Ioniq Hybrid/Plug-In Hybrid (AE HEV/PHEV) vehicles.

 

Part Information:  

Part Name Part Number Qty Note
MAIN RELAY 37583-A8000QQH 1  

Only required based on vehicle inspection results. Refer to Service Procedure.

Note: The main relays are packaged as a set of two.

PRA 37514-G2100QQH 1 Includes new main relays preinstalled.

Only required based on vehicle inspection results.

Refer to Service Procedure.

 

DANGER

The vehicle contains a high voltage battery and associated components. Follow all applicable electrical system precautions outlined in the Shop Manual before performing the procedure.
Shop Manual > General Information > General Safety Information and Caution

 

Service Procedure Flowchart:

WARNING

Follow the high voltage cut off procedure before performing the inspection or any repairs.

1. Tum the ignition switch OFF and disconnect the auxiliary(-) battery negative(-) terminal.

2. Remove the safety plug cover (A).

 

3. Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (8) to the direction of arrow.

 

4. Wait for more than 5 minutes so that the capacitor in the high voltage system can be fully discharged.

Information

Some vehicles may not have their main relay labels visible due to a more recently installed battery pack, resulting in the PRA cover that is not removable. A PRA where the cover is not removable has the latest labels enclosed with ‘Panasonic’.

 


RECALL 232 ATTACHMENT A
CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

March – August 2018

On March 7, 2018, HMC received a report indicating heat damage on the rear seat of model year 2017 Kia Niro sold in the Korean market.  HMC immediately began testing to determine the cause of the damage under various driving conditions and maneuvers.  As of June 2018, HMC was unable to replicate the phenomenon.  HMC began focusing its investigation on component testing with the supplier.  This testing concluded in August 2018 and the phenomenon could not be replicated by component bench testing alone.

 

September 2018

HMC conducted additional testing and on September 18, 2018, HMC was able to replicate the phenomenon.  An inspection of the damaged rear seat revealed that the damage was caused by increased heat generated by the PRA.  Further inspection of the PRA revealed that the main relay was loosely connected, indicating that the heat was likely caused by increased electrical resistance as a result of loose contact between the main relay terminals.  In addition, HMC noted that the main relay originated from a previous supplier that used lower manufacturing specifications for terminal tightening torque and contact pressure.  Main relays provided by the current supplier were produced with higher specifications for terminal tightening torque and contact pressure.

 

October 2018

HMC notified all regional distributors of the affected vehicles and informed them of their findings.  After conducting its own search of related field information, HMA convened its Technical Committee on October 2, 2018, and decided to conduct a voluntary safety recall to address the condition in the subject vehicles.

 

June 2021

On June 26, 2021, HMA received a report of a 2017 Ioniq vehicle that allegedly caught fire after receiving the remedy specified for Recall 178.  HMA’s NASO began monitoring field information for post-remedy fires on all vehicles that were repaired under Recall 178.

 

November – December 2021

On November 29, 2021, HMA received a report of a 2017 Ioniq vehicle that allegedly caught fire after receiving the remedy specified for Recall 178.

On December 20, 2022, HMA was notified of an additional incident involving a previously remedied 2017 Ioniq vehicle that caught fire.  The November and December incident vehicles were available and requested for inspection and further analysis.

 

January – February 2022

NASO recovered two incident vehicles and a joint inspection was performed on February 24, 2022 with representatives from HMC, HMA, and Hyundai’s North American Quality Center (“NAQC”).

Hyundai found that both vehicles were still equipped with the original factory-installed relays despite both vehicle’s repair history displaying the remedy for Recall 178 was previously applied.  The prior remedy for each inspected vehicle was applied by separate dealers.

 

March – May 2022

In March 2022, Hyundai received notice of two (2) additional post-remedy fire cases at two additional dealers.

From March through April 2022, HMA coordinated a survey of vehicles repaired by the subject dealers under Recall 178 to identify additional vehicles that might have been impacted.  NASO identified four (4) vehicles that were improperly repaired, out of eleven (11) total vehicles surveyed, bringing the cumulative count of known incidents to nine (9).

 

April – May

The HMA Audit team conducted a routine warranty audit for one of the previously identified dealers to review all processes related to recall campaign repair, completion, and warranty filings related to Recall 178 and compliance with internal and federal requirements.

 

June 2022

On June 14, 2022, NASO met with several HMA departments to review the audit findings and discuss possible future activity related to recall and campaign compliance.

On June 17, 2022, HMA convened its North America Safety Decision Authority and decided to initiate a new safety recall of all vehicles previously involved in Recall 178 in the U.S. market.

As of the date of this filing, Hyundai has identified nine (9) total reports of the defect condition in the subject vehicle population received from June 26, 2021, through March 6, 2022.  There are no confirmed crashes or injuries related to the subject defect condition in the U.S.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
HYUNDAI IONIQ HYBRID 2017-2018
HYUNDAI IONIQ PLUG-IN HYBRID 2017-2018

 


14 Associated Documents

Recall Acknowledgement

RCAK-22V459-5648.pdf 644.989KB

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ATTACHMENT A: CHRONOLOGY

RMISC-22V459-9707.pdf 125.667KB

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Defect Notice 573 Report

RCLRPT-22V459-7197.PDF 214.064KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V459-8592.pdf 249.068KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V459-2646.pdf 650.867KB

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Remedy Instructions and TSB

RCRIT-22V459-7774.pdf 822.018KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V459-3996.pdf 225.611KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V459-8829.PDF 211.137KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V459-8117.PDF 211.246KB

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ISSUED Renotification Notice

RCRN-22V459-5829.pdf 287.199KB

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ISSUED Renotification Notice

RCRN-22V459-6016.pdf 287.199KB

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Remedy Instructions and TSB

RCRIT-22V459-4148.pdf 621.218KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V459-1817.pdf 638.263KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V459-5216.PDF 211.336KB

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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=22V459&docType=RCL

 


 

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VEVOR Level 2 Portable EV Charger, 32 Amp 240V, Electric Vehicle Charger with 28 ft Charging Cable NEMA 14-50P Plug, 16/20/24/32A Adjustable Current Plug-in Home EV Charging Station for SAE J1772 EVs
  • Portable EV Charger: This portable car charger offers high compatibility with a NEMA 14-50P plug, making it suitable for charging most electric vehicles and plug-in hybrid vehicles that adhere to the J1772 standard.
  • All-Round Protection: Comply with ETL security certification standards. During charging, the portable charger controller automatically adjusts the current according to the charging status to avoid overcharging. It also provides lightning/leakage/grounding/over-voltage/under-voltage/overcharge/over-current/overheat protection.
  • Smart APP Control: Enjoy a great charging experience with the convenience of smart app control. You can not only control and monitor the charging status remotely through the smart APP, but also schedule charging time for 1-12 hours, allowing you to take advantage of off-peak charging and reduce your vehicle usage costs.
  • Extra-Long Charging Cable: Enjoy the flexibility the 28-foot-long charging cable includes with this portable EV charger. You can conveniently charge your EV at home or using public charging stations without hassle. The internal copper wires ensure excellent conductivity, and the external TPE flame-retardant protective jacket is thickened for added durability. The charging cable is IP66 waterproof and dustproof, withstanding temperatures from -30°C to 45°C.
  • Dual-Purpose Functionality: Our package includes a hard-shell storage bag, a base, and a charging cable hook, providing versatile functionality. Using the base and charger holder, you can easily install this charger as a fixed charging station in your garage. Simply store the charging cable in the included storage bag for on-the-go charging and take it with you. You can charge your EV wherever there's an available power outlet.

Last update on 2024-03-27 / Affiliate links / Images from Amazon Product Advertising API

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