Recall 239 Coolant Leak in EPCU May Cause Loss of Drive Power – 2021 Hyundai Kona EV

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December 16, 2022 NHTSA CAMPAIGN NUMBER: 22V941000

Coolant Leak in EPCU May Cause Loss of Drive Power

Coolant contacting the EPCU circuit board may cause a loss of drive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V941

Manufacturer Hyundai Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 853

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2021 Kona EV vehicles. The Electric Power Control Unit (EPCU) may have been improperly sealed and may leak coolant internally.

 

Remedy

Dealers will inspect and replace the EPCU, as necessary, free of charge. Owner notification letters were mailed March 22, 2023. A second notice will be sent once the final remedy is available. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 239.

 

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

 


Recall Description: 

On certain 2021MY Kona Electric (OS EV) vehicles, a low-conductivity coolant may leak inside the Electric Power Control Unit (EPCU) and may cause warning lights to illuminate and/or loss of motive power. The coolant leak is caused by insufficient sealing and housing cleaning omissions. TSB 23-01-018H provides the service procedure on how to inspect the leak and replace the EPCU if a leak is confirmed.

 

Applicable Vehicles:

  • Certain 2021MY Kona Electric (OS EV) produced from 06/18/2020 through 07/31/2020

 

Remedy Information: 

  • Inspect the Electric Power Control Unit (EPCU) and replace the EPCU if the unit does not pass inspection. o Recommended Technician Training Level: Certified or above
    • Recommended Technician Training Courses: Hyundai EV Service Safety series and Kona New Model (SVCH2019OSEVNMTW18_806) web courses on Hyundai Learning Portal (HLP)

 

Recommended Alternative Transportation:Based on the time of the inspection/repair, a Service Rental Car (SRC) should be provided to the customer.

 

Warranty Information:

This campaign pays 1.7 M/H for an EPCU inspection & 3.3 M/H for EPCU inspection and replacement.

  • Op times include taking STUI pictures where necessary and uploading. The STUI photos must include the inspection result of the EPCU and new EPCU installed (if necessary, based on inspection) 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.
  • Three (3) 2L bottles of BSC-2 coolant will also be reimbursed to the dealer when submitting claims for either the EPCU inspection and EPCU inspection/replacement.

 

Acceptable STUI Photo of the Gauge for inspection & Replacement EPCU 

 

Please refer to TSB 23-01-018H (or latest version) for additional details.

 

Parts Information:

  • Please refer to TSB 23-01-018H for the latest parts information.
  • Please consider the following: o EPCU Part Number 36601-0E170QQH: On CSP (Critical Parts Supply). Dealer will require a valid recall 239 VIN to order the part.
    • Special Service Tools below:
      • 1K373-G5100QQH – Adapter Tool (Pressure Hose/Differential Pressure Hose)
      • KQ366-EV001QQH – Coolant Discharge Hose 09580-3D100QQH – Air Bleeding Tool Key Notes:
        • On CSP and manual allocation. The following tools have been provided to most dealers expected to perform the recall.
        • A valid recall VIN will be required when ordering the tools. The tools will be shipped out if it is determined that the dealership has not previously received 1 set of each.

 

Customer Mailing:

  • Owners of the subject vehicles were previously notified via First Class mail of a remedy not available for their vehicle in early February 2023.
  • Update: Owners of the subject vehicles are expected to be notified via First Class mail starting in late March 2023/early April 2023 of a remedy available for their vehicle.

 

Customer Talk Track:

Sample: “During your visit we checked to see if your vehicle has any open recalls. We found that Recall 239 for the electronic power control unit is open on your vehicle. We are going to inspect the electronic power control unit (EPCU) to determine if there is a leak or not. If a leak is present, we will replace the EPCU at no cost to you. The inspection and replacement of the EPCU, if necessary, is important as a leak inside the Electric Power Control Unit (EPCU) may cause warning lights to illuminate and/or loss of motive power, increasing the risk of a crash at certain speeds.

 


FAQ: 

Q1: What is the issue?

A1: The Electric Power Control Unit (“EPCU”) used in the subject vehicles may have been produced by the supplier with insufficient sealing of the EPCU’s DC-DC convertor housing potentially causing an internal coolant leak and contamination of the EPCU main controller. Contamination of the EPCU controller could result in triggering of the vehicle’s limited mobility “fail safe” drive mode or, in limited instances, a sudden loss of motive power or vehicle stall.

 

Q2: What are the affected vehicles?

A2: Certain 2021 model year Hyundai Kona EV vehicles produced from June 18, 2020, through July 31, 2020, by Hyundai Motor Company (“HMC”) for sale in the U.S. market.

 

Q3: What is the safety concern?

A3: A sudden loss of motive power or stall could increase the risk of a crash at certain speed.

 

Q4: Have there been any accidents or injuries?

A4: As of the date of this filing (12/19/2022) to NHTSA, Hyundai has confirmed 3 unique incidents reporting a loss of motive power in the U.S. received from January 2, 2021, through July 6, 2021, in the U.S. There are no confirmed crashes or injuries related to this condition.

 

Q5: Stop Sale?

A5: No, a “stop sale” is not being planned as the affected vehicles are no longer in production.

 

Q6: What will be done during the recall service at the dealer?

A6: All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to inspect the EPCU and replace it, 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.

 

Q7: When will owners be notified of a remedy available for this recall campaign 239?

A7: Owners of the subject vehicles are expected to be notified via First Class mail starting in late March 2023/early April 2023 of a remedy available for their vehicle.

 


23-01-018H
MARCH 2023

ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239)

Description: On certain Kona Electric (OS EV) vehicles a low-conductivity coolant may leak inside the Electric Power Control Unit (EPCU) and may cause warning lights to illuminate and/or loss of motive power. The coolant leak is caused by insufficient sealing and housing cleaning omissions. This bulletin provides information on how to inspect the leak and replace the EPCU if a leak is confirmed.

Applicable Vehicles: Certain 2021MY Kona Electric (OS EV) produced from 06/18/2020 – 07/31/2020

Refer to service procedure video at: https://vimeo.com/803267927/b21bc01099

 

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RECALL 239 ATTACHMENT A
CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

❖November – December 2022

On November 2, 2022, HMC informed HMA’s NASO of a potential internal coolant leak issue involving the EPCU assemblies used in certain model year 2021 Kona EV vehicles in the U.S. market.

On November 18, 2022, NASO’s Data Review Committee (“DRC”) escalated a new investigation for analysis by the Technical Review Committee (“TRC”).  NASO’s TRC confirmed affected models in the U.S. market and performed an analysis of field information for incidents related to the subject condition.

Based on the analysis findings, NASO convened its North America Safety Decision Authority (“NASDA”) on December 9, 2022 and decided to conduct a new safety recall of affected model year 2021 Hyundai Kona EV vehicles in the U.S. to address the defect condition involving the vehicles’ EPCU.

As of the date of this filing, Hyundai has confirmed 3 unique incidents reporting a loss of motive power in the U.S. received from January 2, 2021, through July 6, 2021, in the U.S.  There are no confirmed crashes or injuries related to this condition.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HYUNDAI KONA ELECTRIC 2021

 


12 Associated Documents

Recall Acknowledgement

RCAK-22V941-9054.pdf 645.203KB

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Defect Notice 573 Report

RCLRPT-22V941-1708.PDF 213.801KB

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Attachment A- Chronology

RMISC-22V941-8449.pdf 98.631KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V941-5318.pdf 274.431KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V941-5833.pdf 241.236KB

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Remedy Instructions and TSB

RCRIT-22V941-3474.pdf 1135.022KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V941-0487.pdf 426.818KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V941-9851.pdf 245.408KB

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Recall Quarterly Report #1, 2023-1

RCLQRT-22V941-4497.PDF 211.144KB

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Recall Quarterly Report #2, 2023-2

RCLQRT-22V941-2330.PDF 211.248KB

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ISSUED Renotification Notice – 09/27/2023

RCRN-22V941-6982.pdf 267.545KB

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Recall Quarterly Report #3, 2023-3

RCLQRT-22V941-2909.PDF 211.473KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V941&docType=RCL

 


 

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Portable EV Charger Level 1, 15Amp 110V, Electric Vehicle Charger with 21Ft Extension Cord,NEMA 5-15P for Plug-in Home EV Charging Station,Compatible with SAE J1772 EVs
  • 【LEVEL 1 EV CHARGER】 - The AplysiaTec Level 1 Charger is designed for charge your EV with a standard 110V outlet at home or at work; You get 15 amps and max 1.65 kw of power for the standard full-charge time for your car.If you think 1.65kw is too slowly for your car,please choose the AplysiaTech Level 1+2 charger to access max 3.8kw power when you plug-in 6-20 outlet with 240V Level 2 .You can also choose AplysiaTech Level 2 charger with 50Amp to get your EV fully charged within few hours when you have 14-50R outlet with 6AWG cable. We understand Level 1 charging is slowly,but sometimes that's all available at home.
  • 【CONVENIENT FOR HOME ADN OFFICE CHARGER】 - The Aplysiatech 15 Amp EV Charger is designed for affordable and convenient charging option compared to other Level 2 EV chargers,just plug in 5-15R outlet and then delivering an extra 40-50 miles of overnight charge at home.Super convenient choice for all EV owners.
  • 【SAFE FOR HOME AND OFFICE CHARGER】- AplysiaTech 15 Amp EV charger is IP65 weather-resistant, and with built-in protection against overvoltage, overcurrent, and short circuits;14AWG charing cable for safe and reliable charging at home and office.
  • 【HIGH COMPATIBILITY CHARGER】AplysiaTech EV charger is compatible with electric vehicles that meet SAE J1772 standards. You will need AplysiaTech J1772 to Tesla charger adapter if you are Tesla owner.
  • 【EASY TO CARRY EV CHARGER】No worry about charging while traveling or on business,AplysiaTech 15Amp portable EV charger included storage bag to makes it easy to carry around and stay organized in your car, allowing you to charge anywhere and anytime, no need to find an EV charging station outside.

Last update on 2024-04-26 / Affiliate links / Images from Amazon Product Advertising API

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