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 Labor operation codes applicable to the superseded recall and vehicle models will be deactivated and related claims must be submitted by 08/25/2022.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
14 Associated Documents
Recall Acknowledgement
RCAK-22V459-5648.pdf 644.989KB
ATTACHMENT A: CHRONOLOGY
RMISC-22V459-9707.pdf 125.667KB
Defect Notice 573 Report
RCLRPT-22V459-7197.PDF 214.064KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V459-8592.pdf 249.068KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V459-2646.pdf 650.867KB
Remedy Instructions and TSB
RCRIT-22V459-7774.pdf 822.018KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V459-3996.pdf 225.611KB
Recall Quarterly Report #1, 2022-3
RCLQRT-22V459-8829.PDF 211.137KB
Recall Quarterly Report #2, 2022-4
RCLQRT-22V459-8117.PDF 211.246KB
ISSUED Renotification Notice
RCRN-22V459-5829.pdf 287.199KB
ISSUED Renotification Notice
RCRN-22V459-6016.pdf 287.199KB
Remedy Instructions and TSB
RCRIT-22V459-4148.pdf 621.218KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V459-1817.pdf 638.263KB
Recall Quarterly Report #3, 2023-1
RCLQRT-22V459-5216.PDF 211.336KB
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SEOCONTENT-START
Web version #FIRST NAME, A Safety Recall has been issued on your 2017 Ioniq Hybrid/Plug-In Hybrid’s Power Relay Assembly (PRA).Recall 232 Remedy is Available This notice applies to your vehicle, VIN: XXXXXXXXXXXXXXXXX What Should You Do? Our records indicate that your vehicle is affected. Hyundai has prepared a remedy repair for your vehicle, which will be performed by your Hyundai dealer at NO CHARGE . To ensure your safety and the quality of your vehicle, please schedule an appointment with a Hyundai dealer as soon as possible to complete the remedy procedure. Additional Information NHTSA.GOV HYUNDAIUSA.COM PRIVACY You are receiving this notice because our records indicate that you own or lease the vehicle identified by the VIN on this notice. This is an outbound email only. Please do not reply to this email. This message was transmitted by Hyundai Motor America. Hyundai is a registered trademark of Hyundai Motor Company. Hyundai model names are registered trademarks of Hyundai Motor America. All rights reserved.©2023 Hyundai Motor America. Learn more about the safety concern and remedy repair by visiting Hyundai’s official site or the NHTSA website. If you require further assistance, such as questions on reimbursement or updating vehicle ownership, please visit the Hyundai Consumer Assistance Center or by contacting Hyundai Motor America at 1-855-371-9460. To better assist you during your call please have the last 8 characters of your VIN ready to enter when prompted. Last 8 Characters: HU036516
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Web version #FIRST NAME, A Safety Recall has been issued on your 2017 Ioniq Hybrid/Plug-In Hybrid’s Power Relay Assembly (PRA). Recall 232 Remedy is Available This notice applies to your vehicle, VIN: XXXXXXXXXXXXXXXXX What Should You Do? Our records indicate that your vehicle is affected. Hyundai has prepared a remedy repair for your vehicle, which will be performed by your Hyundai dealer at NO CHARGE. To ensure your safety and the quality of your vehicle, please schedule an appointment with a Hyundai dealer as soon as possible to complete the remedy procedure. Additional Information NHTSA.GOV HYUNDAIUSA.COM PRIVACY You are receiving this notice because our records indicate that you own or lease the vehicle identified by the VIN on this notice. This is an outbound email only. Please do not reply to this email. This message was transmitted by Hyundai Motor America. Hyundai is a registered trademark of Hyundai Motor Company. Hyundai model names are registered trademarks of Hyundai Motor America. All rights reserved. ©2023 Hyundai Motor America. Learn more about the safety concern and remedy repair by visiting Hyundai’s official site or the NHTSA website. If you require further assistance, such as questions on reimbursement or updating vehicle ownership, please visit the Hyundai Consumer Assistance Center or by contacting Hyundai Motor America at 1-855-371-9460. To better assist you during your call please have the last 8 characters of your VIN ready to enter when prompted. Last 8 Characters: HU036516
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Circulate To: General Manager, Service Manager, Sales Manager, Parts Manager, Warranty Manager, Service Advisors, Technicians, Body Shop Manager, Fleet Repair Technical Service Bulletin GROUP NUMBER RECALL 23-01-024H DATE MODEL(S) MARCH 2023 IONIQ HYBRID (AE HEV) IONIQ PLUG-IN (AE PHEV) SUBJECT: 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. 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 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 veh icle is in the shop for any maintenance or repair. Access the “Vehicle Information” screen via WEBDCS to identify open recalls. IMPORTANT This TSB includes STUI p hoto (s) as a STUI p hoto (s) requires adding a paper note with the RO date and last 6 of VIN to be clearly visible in the photos . P lease ensure captured p hoto( s) are done according to the steps in this TSB and uploaded to STUI once completed. All claims found that have incomplete , missing, o r incorrect p hoto( s) ar e subject to debit. STUI IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 2 of 7 SUBJECT: SUBJECT: Applicable Vehicles: Certain 2017-2018 MY Ioniq Hybrid/Plug-In Hybrid (AE HEV/PHEV) vehicles. Part Information: Part Name Part Number / Figure 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. Warranty Information: Model Op. Code Operation Op. Time Causal Part No. Nature Code Cause Code IONIQ HYBRID/ PLUG-IN HYBRID (AE HEV / AE PHEV) 22R178R0 MAIN RELAY LABEL INSPECTION 0.4 M/H 37514-G2100QQH I3A ZZ3 22R178R1 MAIN RELAY LABEL INSPECTION, PRA INSPECTION, AND MAIN RELAY REPLACEMENT 0.9 M/H 37514-G2100QQH 22R178R2 MAIN RELAY LABEL INSPECTION, PRA INSPECTION, AND PRA REPLACEMENT 0.9 M/H 37514-G2100QQH Notes: 1) Submit Claim on Campaign Claim Entry Screen. 2) If a part is found in need of replacement while performing this recall and the affected part is still under warranty, submit a separate claim using the same repair order. If the affected part(s) are out of warranty, request a Prior Approval request for goodwill consideration prior to completing the recall. 3) The incident parts are subject to callback through the normal Warranty Technical Center (WTC) parts return process. Claim is subject to debit if the part is not returned. 4) If the main relays are not visible due a covered PRA from a recent battery pack replacement, please submit op code 22R178R0. 5) Op times include taking STUI photo(s) and uploading. The STUI photo(s) must include the labels of the main relays with `Panasonic’ or of the covered PRA (if this scenario encountered) along with a piece of paper displaying the last 6 digits of the VIN and date of the repair. If not included, claim will be subject to debit. IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 3 of 7 SUBJECT: SUBJECT: Service Procedure Flowchart: The vehicle contains a high voltage battery and associated components. Follow The vehicle contains a high voltage battery and associated components. Follow all applicable electrical system precautions outlined in the Shop Manual before all applicable electrical system precautions outlined in the Shop Manual before performing the performing the procedure.procedure. Shop Manual > Shop Manual > General Information > General Safety Information and CautionGeneral Information > General Safety Information and Caution DANGER DANGER ! ! Follow the high voltage cut Follow the high voltage cut–off procedure before performing the inspection or off procedure before performing the inspection or any repairs.any repairs. WARNING WARNING ! ! IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 4 of 7 SUBJECT: SUBJECT: Some vehicles may not have their main relay labels visible due to a more recently installed 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 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’.removable has the latest labels enclosed with ‘Panasonic’. Information Information ii IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 5 of 7 SUBJECT: SUBJECT: IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 6 of 7 SUBJECT: SUBJECT: IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPA IGN 232) TSB #: 23-01-024H Page 7 of 7 SUBJECT: SUBJECT:
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This notice applies to your Hyundai, VIN: XXXXXXXXXXXXXXXXX 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 certain 2017 – 2018 Ioniq Hybrid/Plug-In Hybrid vehicles. Hyundai is initiating Recall Campaign 232 a safety recall to repair a condition involving the power relay assembly in these vehicles in the U.S. Hyundai is conducting this action to ensure the safety of its vehicles for Hyundai customers. Our records indicate that your vehicle is affected by this recall campaign. What is the problem? The subject vehicles may not have received the proper remedy components under Recall 178 (NHTSA Recall 18V-704), 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. What will Hyundai do? Your Hyundai dealer will inspect if the previously applied remedy components were installed and if necessary, install the remedy components (main power relay or PRA). This procedure will be performed at NO CHARGE to you. What should you do? Please contact your nearest Hyundai dealer to schedule this procedure by visiting www.HyundaiUSA.com/us/en/dealer-locator or calling 1-855-371-9460. The actual time required to perform this procedure on your vehicle will take less than one hour, however, your vehicle may be needed longer. Therefore, we recommend scheduling a service appointment to minimize inconvenience. If you have other questions 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 without charge, or 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 2017 – 2018 Ioniq Hybrid and Plug-In Hybrid Power Relay Assembly Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8” NHTSA Recall Number: 22V-459 Hyundai Recall Number: 232 This is an important Safety Recall. • Please contact your nearest Hyundai dealer to schedule this procedure as soon as possible. • The recall will be performed on your vehicle at NO CHARGE to you. • To locate your nearest Hyundai dealer and schedule your appointment please visit: www.HyundaiUSA.com/Campaign232 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 https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/campaign.html; or call 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.
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Circulate To: General Manager, Service Manager, Sales Manager, Parts Manager, Warranty Manager, Service Advisors, Technicians, Body Shop Manager, Fleet Repair Technical Service Bulletin GROUP NUMBER RECALL 23-01-024H DATE MODEL(S) MARCH 2023 IONIQ HYBRID (AE HEV) IONIQ PLUG-IN (AE PHEV) SUBJECT: 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. 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 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. Access the “Vehicle Information” screen via WEBDCS to identify open recalls. IMPORTANT This TSB includes STUI photo(s) as a requirement. STUI photo(s) requires adding a paper note with the RO date and last 6 of VIN to be clearly visible in the photos. Please ensure captured photo(s) are done according to the steps in this TSB and uploaded to STUI once completed. All claims found that have incomplete, missing, or incorrect photo(s) are subject to debit. STUI <8) HYUnDRI IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 2 of 7 SUBJECT: SUBJECT: Applicable Vehicles: Certain 2017-2018 MY Ioniq Hybrid/Plug-In Hybrid (AE HEV/PHEV) vehicles. Part Information: Part Name Part Number / Figure 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. Warranty Information: Model Op. Code Operation Op. Time Causal Part No. Nature Code Cause Code IONIQ HYBRID/ PLUG-IN HYBRID (AE HEV / AE PHEV) 22R178R0 MAIN RELAY LABEL INSPECTION 0.4 M/H 37514- G2100QQH I3A ZZ3 22R178R1 MAIN RELAY LABEL INSPECTION, PRA INSPECTION, AND MAIN RELAY REPLACEMENT 0.9 M/H 37514- G2100QQH 22R178R2 MAIN RELAY LABEL INSPECTION, PRA INSPECTION, AND PRA REPLACEMENT 0.9 M/H 37514- G2100QQH Notes: 1) Submit Claim on Campaign Claim Entry Screen. 2) If a part is found in need of replacement while performing this recall and the affected part is still under warranty, submit a separate claim using the same repair order. If the affected part(s) are out of warranty, request a Prior Approval request for goodwill consideration prior to completing the recall. 3) The incident parts are subject to callback through the normal Warranty Technical Center (WTC) parts return process. Claim is subject to debit if the part is not returned. 4) If the main relays are not visible due a covered PRA from a recent battery pack replacement, please submit op code 22R178R0. 5) Op times include taking STUI photo(s) and uploading. The STUI photo(s) must include the labels of the main relays with `Panasonic’ or of the covered PRA (if this scenario encountered) along with a piece of paper displaying the last 6 digits of the VIN and date of the repair. If not included, claim will be subject to debit. IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 3 of 7 SUBJECT: SUBJECT: Service Procedure Flowchart: 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 ! DANGER Follow the high voltage cut-off procedure before performing the inspection or any repairs. ! WARNING -• 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. IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 4 of 7 SUBJECT: SUBJECT: 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’. □ i Information Vehicle In IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 5 of 7 SUBJECT: SUBJECT: NO: one or both labels do not state “Panasonic” and/or not covered. Remove the full PRA Assembly as per shop manual procedure: • YES: both labels state “Panasonic”: OR YES: A covered PRA has the latest “Panasonic” labels enclosed. IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 6 of 7 SUBJECT: SUBJECT: YESda11111p –~- NO DAMAGE IONIQ HEV/PHEV MAIN RELAY / POWER RELAY ASSY REPLACEMENT (RECALL CAMPAIGN 232) TSB #: 23-01-024H Page 7 of 7 SUBJECT: SUBJECT: Vehicle Complete
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-459 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Hyundai Motor America Submission Date : JUN 28, 2022 NHTSA Recall No. : 22V-459 Manufacturer Recall No. : 232 Manufacturer Information : Manufacturer Name : Hyundai Motor America Address : 10550 Talbert Avenue Fountain Valley CA 92708 Company phone : 800-633-5151 Population : Number of potentially involved : 10,575 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2017-2018 Hyundai Ioniq HEV Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : The subject population includes all previously recalled model year 2017-2018 Hyundai Ioniq Hybrid vehicles specified for Recall 178. Production Dates : NOV 16, 2016 – AUG 16, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2017-2018 Hyundai Ioniq PHV Vehicle Type : LIGHT VEHICLES Body Style : 4-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : The subject population includes all previously recalled model year 2017-2018 Hyundai Ioniq Plug-In Hybrid vehicles specified for Recall 178. Production Dates : AUG 10, 2017 – AUG 11, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : 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. FMVSS 1 : NR FMVSS 2 : NR Part 573 Safety Recall Report 22V-459 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Safety Risk : Increased electrical resistance between the main relay contacts can increase the risk of a thermal event, including the potential for a fire. Description of the Cause : Loose connection between the main relay contacts. Identification of Any Warning that can Occur : Illumination of the HEV warning light while driving and/or an inability to start the vehicle. Involved Components : Component Name 1 : PRA Component Description : POWER RELAY ASSEMBLY Component Part Number : 37514-G2100QQH Component Name 2 : MAIN RELAY Component Description : Main relay within PRA Component Part Number : 37583-A8000QQH Supplier Identification : Component Manufacturer Name : LS IS CO., Ltd Address : 95, Beakbong-ro Heung deok-gu Chungju-si, Chungcheongbuk-do Foreign States Country : Korea, Republic of Chronology : Please see Attachment A for the requested chronology of events leading up to defect decision. Part 573 Safety Recall Report 22V-459 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : All owners of the affected 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 relay or 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. Additionally, 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. How Remedy Component Differs from Recalled Component : The new main relay is produced by a different supplier and ensures a proper connection between the main relay contacts. Identify How/When Recall Condition was Corrected in Production : The new main relays were used in all of production starting from August 16, 2017. Recall Schedule : Description of Recall Schedule : Dealers and owners will be notified in accordance with the specified dates. Planned Dealer Notification Date : AUG 26, 2022 – AUG 26, 2022 Planned Owner Notification Date : AUG 26, 2022 – AUG 26, 2022 * NR – Not Reported
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