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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 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.
- Special Service Tools below:
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
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
Defect Notice 573 Report
RCLRPT-22V941-1708.PDF 213.801KB
Attachment A- Chronology
RMISC-22V941-8449.pdf 98.631KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V941-5318.pdf 274.431KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-22V941-5833.pdf 241.236KB
Remedy Instructions and TSB
RCRIT-22V941-3474.pdf 1135.022KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V941-0487.pdf 426.818KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V941-9851.pdf 245.408KB
Recall Quarterly Report #1, 2023-1
RCLQRT-22V941-4497.PDF 211.144KB
Recall Quarterly Report #2, 2023-2
RCLQRT-22V941-2330.PDF 211.248KB
ISSUED Renotification Notice – 09/27/2023
RCRN-22V941-6982.pdf 267.545KB
Recall Quarterly Report #3, 2023-3
RCLQRT-22V941-2909.PDF 211.473KB
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-941 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Hyundai Motor America Submission Date : DEC 16, 2022 NHTSA Recall No. : 22V-941 Manufacturer Recall No. : 239 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 : 853 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2021-2021 Hyundai Kona EV Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : HYBRID ELECTRIC Descriptive Information : The subject population includes 853 model year 2021 Hyundai Kona EV vehicles produced on June 18, 2020, through July 31, 2020, by Hyundai Motor Company (“HMC”) for sale in the U.S. market. Production Dates : JUN 18, 2020 – JUL 31, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : 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. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A sudden loss of motive power or stall could increase the risk of a crash at certain speed. Description of the Cause : The EPCU’s DC-DC convertor housing was insufficiently sealed due to inadequate steam cleaning during manufacturing. Identification of Any Warning A. Malfunction Indicator Lamp (“MIL”) illumination B. “Check Electric Vehicle System” warning message on information Part 573 Safety Recall Report 22V-941 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 that can Occur : display Involved Components : Component Name 1 : EPCU ASSY Component Description : Electric Power Control Unit Assembly Component Part Number : 36601-0E170 Supplier Identification : Component Manufacturer Name : Hyundai Mobis Address : 203 Teheran-ro Gangnam-gu Seoul Foreign States 06141 Country : Korea, Republic of Chronology : Please see Attachment A for the requested chronology of events leading up to the defect decision. Description of Remedy : Description of Remedy Program : 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. How Remedy Component Differs from Recalled Component : The remedied EPCU’s DC-DC convertor is produced with sufficient sealing to prevent leakage. Identify How/When Recall Condition was Corrected in Production : The duration of the steam cleaning process was revised on July 6, 2020, at the supplier. Part 573 Safety Recall Report 22V-941 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Recall Schedule : Description of Recall Schedule : Dealers and owners will be notified in accordance with the specified dates. Planned Dealer Notification Date : FEB 14, 2023 – FEB 14, 2023 Planned Owner Notification Date : FEB 14, 2023 – FEB 14, 2023 * NR – Not Reported
**************************************************************************************************************
Recall 239: Electric Power Control Unit Remedy Not Available – Dealer Best Practice December 20, 2022 Recall Description: The Electric Power Control Unit (“EPCU”) used in the subject vehicles may have been manufactured 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. Affected Vehicles: • Certain 2021MY Kona Electric (OS EV) produced from 06/18/2020 through 07/31/2020 • To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS. Remedy Information: The remedy is currently under development and additional information will be provided once it has been developed for release. Training recommendations will also be made available when the remedy is ready. Recommended Alternative Transportation: A Service Rental Car (SRC) should be provided if the customer does not feel safe operating their vehicle until the remedy has been performed. Customer Talk Tracks “The electronic power control unit in your vehicle may leak coolant internally due to insufficient sealing. If this were to occur the malfunction indicator light (MIL) may illuminate, the vehicle may go into limp mode or lose power. This unexpected loss of power may result in a crash, especially at high speeds. Once a remedy is available Hyundai will notify you via First Class mail advising you to bring your vehicle to a Hyundai dealership to have it applied at no cost to you.” Best Practice Checklist Reservation: Did you check WebDCS for additional campaigns or recalls? □ Yes □ No Reception: Did you offer the customer a Service Rental Car (SRC) if they do not feel comfortable operating their vehicle until a remedy becomes available? □ Yes □ No Parts: The parts information section will be updated once a remedy becomes available. Warranty: The warranty information section will be updated once a remedy becomes available. Updates to this Document Date • Recall 239: Electric Power Control Unit – Remedy Not Available 12/20/2022 Customer FAQ: Q1: What is the issue? A1: The Electric Power Control Unit (“EPCU”) used in the subject vehicles may have been manufactured 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 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 especially at high speeds. Q4: Have there been any accidents or injuries? A4: 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. 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: Once an official remedy is available, 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 remedy completed free of charge, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty. 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? A7: Owners will be notified in February 2023. Contact Reference: Please see the following page for commonly referred to contacts. Thank you for your prompt attention to this important safety matter and continued commitment to Hyundai customers. Key Contact Information Dealer Support Contact Information Description Parts Techline Warranty HELPREP Line Warranty Prior Approval (PA) Center Xtime Technical Support AutoLoop Technical Support CDK Technical Support Customer Support Hyundai Customer Care Center (Recall /Campaign Questions) Hyundai Recall /Campaign Website Hyundai Customer Care Center (GeneralQuestions) Hyundai Roadside Assistance HyundaiPartsHotline@MobisUSA.com 1-800-545-4515 1‐800‐325‐6604 1‐877‐446‐2922 PA@hmausa.com Support@xtime.com 1‐866‐984‐6355 Support@autoloop.com 1-877-850-2010 https://serviceconnect.support.cdk. com/ Contact Information 1‐855‐671‐3059 www.hyundaiusa.com/recall 1‐800‐633‐5151 1-800-243-7766 Parts ordering hotline Vehicle Technical Support for Hyundai Dealer Technicians Warranty Claim questions for Hyundai Dealers Warranty Prior Approval (PA) Center for Hyundai Dealers Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Description Customer questions or concerns related to recall or service campaigns Updated information related to the specific recall or service campaign Customers general questions, non‐campaign related 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 Car Care Scheduling (Xtime) – Recall Appointment Notification Parts – Campaign Parts Management (CPM) Procedure Service Rental Car (SRC) Program Technical Service Bulletin (TSB) Uncompleted Campaign VIN Listing Recall Campaign Website NHTSAWebsite www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling 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” As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management 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 www.HyundaiDealer.com > Service tab > Hyundai Tech Info A listing of vehicles is located on WEBDCS > SERVICE tab > select UNCOMPLETED CAMPAIGN VIN LISTING – Dealer Stock (New, SRC, CPO, etc.) and Retailed. www.hyundaiusa.com/recall www.safercar.gov Appendix Historical Reference Date • Recall 239 Electric Power Control Unit – Remedy Not Available 12/20/2022
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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 2021 Model Year Kona EV vehicles. To ensure the safety of its vehicles for Hyundai customers, we are initiating Safety Recall 239 to repair a condition involving the Electric Power Control Unit (“EPCU”) in these vehicles in the U.S. Our records indicate that your vehicle is affected by this recall. 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 preparing 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 Electric Power Control Unit (“EPCU”) may have been improperly sealed, 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 and a sudden loss of drive power or vehicle stall, which could increase the risk of a crash. What should you do in the interim? We appreciate your patience. Hyundai is currently preparing to implement the recall remedy. You will receive a second notification letter when the remedy is available. If you have further questions regarding this recall or notice, you can reach out to Hyundai Motor America by calling 1-855-371-9460. For updated information regarding this recall, please visit: www.hyundaiusa.com/campaign239 Additional information 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 Electric Power Control Unit Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8” NHTSA Recall Number: 22V-941 Hyundai Recall Number: 239 This is an important Safety Recall. • We are currently preparing the remedy. We will notify you when the remedy is available. • To stay up to date about this safety recall or for more information, you can visit: www.hyundaiusa.com/campaign239 This notice applies to your 2021 Hyundai Kona EV vehicle, VIN: XXXXXXXXXXXXXXXXX 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. Looking for more information about this Safety Recall? To learn more about this safety recall, including remedy repair status and other commonly asked questions, please visit: www.hyundaiusa.com/campaign239 Need to update ownership? For changes to your name, address, or contact information, please update that information online at: https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/ update-vehicle-ownership.html No longer own this vehicle? If you no longer own this vehicle and know the new owner, please refer them to the above URL. However, if you do not know the new owner, no further action by you is required. IMPORTANT SAFETY RECALL Updated Recall Information: Update Vehicle Ownership: To Call Hyundai: QR codes for easy access You can easily connect with Hyundai Motor America via webpage or phone call by pointing your smartphone camera (or QR code reader app) at the QR code(s) below. Then select the link that will be displayed on your phone. Hyundai Motor America P.O. Box 20839 Fountain Valley, CA 92728-9937 NHTSA Recall Number: 22V-941 Hyundai Recall Number: 239
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(B)HYUnDRI Web version ##SM FMT PROPERCASE[\customer first_name ]##, A Safety Recall has been issued on your ##model_year## ##SMFMT_PROPERCASE[\model_short_name]##’s Electric Power Control Unit. Recall ##campaign_number## Remedy is Available This notice applies to your vehicle, VIN: ##VIN## What will Hyundai do? Your Hyundai dealer will inspect the Electric Power Control Unit (EPCU) and replace it, if necessary. This procedure will be performed 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. Schedulle appointment What is the problem? The EPCU may have been improperly sealed, 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 and a sudden loss of drive power or vehicle stall. A loss of power while driving could increase the risk of a crash. Our records indicate that your vehicle is affected. ——- Additional Information For more information about this critical recall including affected vehicles or frequently asked questions, you may view HY.undai’s official camP-aign P-ag~ or visit the NHTSA website. If you require further assistance, including info on reimbursement or updating ownership, please visit the HY.undai Consumer Assistance Center or by calling the Hyundai Motor America Virtual Assistant at 1-855-3 71-9460. To better assist you during your call please have the last 8 characters of your VIN ready to enter when prompted. Last 8 Characters: ##last_S_ vin## (8)HYUnDRI NHTSA.GOV HYUNDAIUSA.COM PRIVACY 0 9 0 0 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.
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Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service Advisors, Technicians, Body Shop Manager, Fleet Repair GROUP RECALL NUMBER 23-01-018H Technical Service Bulletin DATE MARCH 2023 MODEL(S) KONA Electric (OS EV) SUBJECT: 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 Parts Information: Part Name Part Number Remarks Coolant (Low Conductivity) EPCU 00232-19111 Note: If 00232-19111 is no longer available, use 00232-19113. 36601-0E170QQH 3 qty. of BSC2, 2L Bottle (6L required per vehicle) Only order as required after an inspection FAIL result. 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. 🞳 TANT This TSB includes STUI pictures as a requirement. Please include the last 6 digits of the VIN and date of repair on a piece of paper. Ensure the VIN and date of repair are clearly visible. Finally, please ensure all captured pictures are completed according to the steps in this TSB and uploaded to STUI. All claims submitted that have illegible, incomplete, or incorrect picture(s) are subject to debit. STUI SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) Tools Information: NOTE: • The following tools have been provided to most dealers expected to perform this recall. • A valid recall VIN will be required when ordering the tools. The tools will be shipped out if it determined that the dealership has not previously received 1 set of each. • These tools can be used for multiple vehicles. Part Name Figure / Part Number Remarks NOTE: • This new improved tool with part number ending in QQH and must be used for this recall. • Do not use a prior version of this tool not ending in QQH. Air Bleeding Tool (NOTE: This is a revised version of exist ing tool at dealers) 09580-3D100QQH X OK Adapter Tool (Pressure Hose/ Differential Pressure Hose) 1K373-G5100QQH • 1 qty. Kit Coolant Discharge Hose KQ366-EV001QQH • 1 qty. • The length of the hose provided is 1M (39.4 in). • For first time use, cut 16in (40cm) from the end and use the remaining 26in (60cm) of the hose. TSB #: 23-01-018H Page 2 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) Warranty Information: MODEL OP CODE OPERATION OP TIME CAUSAL PART NATURE CODE CAUSE CODE Kona EV (OS EV) Kona EV (OS EV) 21D184R0 21D184R1 EPCU Leak Inspection EPCU Leak Inspection and EPCU Replacement 1.7 M/H 3.3 M/H 36601-0E170QQH 36601-0E170QQH I3A I3A ZZ7 ZZ7 NOTE 1: Submit claim on Campaign Claim Entry screen. NOTE 2: If a part is found in need of replacement while performing the repair for this recall and the affected part is still under warranty, submit a separate 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 3: Three (3) qty. of 2L bottles of BSC-2 Coolant will be reimbursed under both labor operations. NOTE 4: Op time includes taking STUI pictures 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. NOTE 5: 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. TSB #: 23-01-018H Page 3 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) Service Procedure: Refer to service procedure video at: https://vimeo.com/803267927/b21bc01099 Designates STUI Photo upload required with piece of paper showing last 6 of VIN and RO date. Gauge result Gauge result NOTE: includes 30 mins of GDS bleeding by EWP run function. EPCU Part removed Vehicle Out TSB #: 23-01-018H Page 4 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) 1. Open the hood and remove the engine cover. Open the reservoir cap (A) and remove the service interlock connector (B) to cut the high voltage connection and wait 5 minutes for A capacitors to discharge. Record Radio Presets while waiting the 5 mins. ! CAUTION Refer to the shop manual: B • Battery Control System > High Voltage Shut-off Procedures • Also remove the 12V auxiliary battery negative terminal. 2. Lift the vehicle, remove the splash shield, and open the coolant drain plug (C) to drain the coolant. ! CAUTION Wear safety glasses to protect from coolant splash into your eyes. C NOTICE Place the container on the floor to catch coolant as it drains downward. Gravity Drain TSB #: 23-01-018H Page 5 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) 3. Disconnect the on-board charger (OBC) cooling hose (D). D 4. Disconnect the EPCU cooling hose (E). E TSB #: 23-01-018H Page 6 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) 5. Connect the coolant discharge hose (F) supplied to the EPCU nipple. i Information 1. For the first use, cut 16in (40cm) from the end of the 1M coolant discharge hose (F) and use the remaining 26in F (60cm). If already at 26in, no further cutting is required. 2. Due to the curvature of the hose, it may spray coolant to the front or rear if it is not facing down when draining the coolant. 1. Feed the discharge hose through to the bottom of the vehicle to a bucket placed underneath to catch coolant that will be discharged from the hose later. F 6. Connect the pressure hose (H) of the adapter tool supplied to the OBC nipple. H TSB #: 23-01-018H Page 7 of 9 SUBJECT: ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) 7. Connect air pressure hose specific to this recall (09580-3D100QQH) to the air bleeding tool and inject air at a pressure of 2 to 2.5 bar for about 30 seconds to drain the residual coolant inside the OBC and EPCU. 8. After the residual coolant drain is finished, remove the coolant discharge drain hose that was connected to the EPCU side, and install the differential pressure hose (I) of the adapter tool. 9. Pressurize at the setting “2 Bar” with the air bleeding tool. Pressurized Drain I i Information 3. Remove the air hose after setting the air bleeding tool to 2 Bar. 2 Bar NOTICE When pressurized using the air bleeding tool, any instantaneous increase in pressure other than the set pressure of 2 bar, can cause the EPCU and OBC to fail. 0 Bar TSB #: 23-01-018H Page 8 of 9 ELECTRIC POWER CONTROL UNIT (EPCU) LEAK INSPECTION AND REPLACEMENT (RECALL 239) TSB #: 23-01-018H Page 9 of 9 SUBJECT: 10. Lock the pressure valve and check that it is airtight after 30 minutes. 1) PASS: If the internal pressure of the coolant is maintained at 1.8 to 2 bar, reinstall vehicle in the reverse order of removal and finish the operation. 2) FAIL: If the internal pressure of the coolant is less than 1.8 Bar (the gauge scale has reduced by more than 1 increment), then replace with a new EPCU. 11. After installing in the reverse order of removal, perform a full 30 mins of GDS EWP operation coolant bleeding and replenish with new coolant as specified in the Parts Info. 12. Reprogram customer’s preset radio stations. 13. Procedure is complete -> Vehicle Out. EPCU Refer to the shop manual for EPCU replacement: • Vehicle Control System > Electric Power Control Unit (EPCU) • NOTE: Ignore the EPCU step to perform air tightness check as it is not necessary for the new part. NOTICE FAIL PASS Using STUI, take a photo of the gauge scale (for either a PASS or FAIL result) with the last 6 digits of the VIN and date of the repair on a piece of paper. Upload the photo to STUI. STUI After EPCU replacement, include a STUI photo of the replacement part. Include the last 6 digits of the VIN and date of the repair on a piece of paper. Upload the photo to STUI. STUI Last 6 Digits of VIN:123456 Date of Repair: 03/02/23 Last 6 Digits of VIN: Date of Repair: 03/02/23
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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 2021 Model Year Kona EV vehicles. To ensure the safety of its vehicles for Hyundai customers, we are initiating Safety Recall 239 to repair a condition involving the Electric Power Control Unit in these vehicles in the U.S. Our records indicate that your vehicle is affected by this recall. What is the problem? The Electric Power Control Unit (“EPCU”) may have been improperly sealed, 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 and a sudden loss of drive power or vehicle stall, which could increase the risk of a crash. What will Hyundai do? Your Hyundai dealer will inspect the EPCU and replace it, if necessary. This procedure will be performed at NO CHARGE to you. What should you do? Please contact your nearest Hyundai dealer to schedule this procedure. The actual time required to perform this procedure on your vehicle will take less than one hour, however, your vehicle may be needed longer. To find your Hyundai dealer in order to schedule an appointment: • Visit www.hyundaiusa.com/dealer-locator and enter your zip code to locate a nearby Hyundai dealer. • Scan QR code shown at right with your smartphone camera to access the online Hyundai dealer locator. • Contact Hyundai Motor America at 1-855-371-9460 and select Option 3 for the Dealer Locator. – When calling, please have available the last 8 characters of your VIN (written in bold characters at the top of this notice). Additional information If you believe that the dealer and/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 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 Electric Power Control Unit Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8” NHTSA Recall Number: 22V-941 Hyundai Recall Number: 239 This is an important Safety Recall. • Failure to complete this recall repair could result in triggering of the vehicle’s limited mobility “fail safe” drive mode and a sudden loss of drive power or vehicle stall, which could increase the risk of a crash. • The repair procedure will be performed on your vehicle at NO CHARGE to you. • Hyundai recommends contacting your preferred dealer and scheduling an appointment in advance to avoid any inconvenience. To locate your nearest Hyundai dealer and schedule your appointment please visit: www.hyundaiusa.com/campaign239 Scan to locate Hyundai dealer This notice applies to your 2021 Hyundai Kona EV vehicle, VIN: XXXXXXXXXXXXXXXXX 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. Do you want to learn more about this Safety Recall and schedule your appointment? To learn more about this safety recall, including the remedy repair, and other commonly asked questions, and how best to schedule your appointment, please visit: www.hyundaiusa.com/campaign239 Have you previously paid for this repair? If you have previously paid for a repair that addresses the issue described in this letter, you may be eligible for a reimbursement. Use the link shown at right to submit your reimbursement request, or to obtain additional information, call 1-855-371-9460. owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/campaign.html No longer own this vehicle? You received this notification because U.S. federal regulations require automotive manufacturers to notify last known owners of recalled vehicles based on current owner records. Our records are based primarily on state registration and title data, which indicate that you are the current owner. If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. IMPORTANT SAFETY RECALL Updated Recall Information: To Call Hyundai: Reimbursement Request: QR codes for easy access You can easily connect with Hyundai Motor America via webpage or phone call by pointing your smartphone camera (or QR code reader app) at the QR code(s) below. Then select the link that will be displayed on your phone. Hyundai Motor America P.O. Box 20839 Fountain Valley, CA 92728-9937 NHTSA Recall Number: 22V-941 Hyundai Recall Number: 239
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&nRecall 239: Electric Power Control Unit (EPCU) Leak Inspection and Replacement – Dealer Best Practice March 03, 2023 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 o 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. Updates to this Document Date • Recall 239: TSB 23-01-018H has been published – Remedy Available 03/03/2023 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 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. To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS. 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. o 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: 1) On CSP and manual allocation. The following tools have been provided to most dealers expected to perform the recall. 2) 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. Best Practice Checklist: Reservation: Did you check WebDCS for additional campaigns or recalls and review the customer’s repair history for additional needs? □ Yes □ No Readiness: Does the dealership have the air bleeding tool, adapter tool (pressure hose/difference pressure hose), coolant discharge hose, and three (3) 2L bottles of BSC-2 Coolant in stock as per TSB 23-01-018H? □ Yes □ No Reception: Did you get permission from the customer to perform the eMPI and review all declined services and additional recommended maintenance? □ Yes □ No Reception: Did you explain to the customer the expected repair time and an expectation for a status update? □ Yes □ No Reception: Did you offer the customer Alternative Transportation? □ Yes □ No Repair: Did you review the results of the eMPI with the customer and provide the customer with estimates for any recommendations and also an adjusted promise time based on any additional services? □ Yes □ No Repair: Is the technician a Hyundai Certified technician (or above)? □ Yes □ No Repair: Per TSB 23-01-018H, was a STUI picture taken for the inspection of the EPCU and if necessary, also in the event the EPCU needs? □ Yes □ No Return: Did you get the customer’s signature on all warranty lines in addition to the final RO? □ Yes □ No 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. Contact Reference: Please see the following page for commonly referred to contacts. Thank you for your prompt attention to this important safety matter and continued commitment to Hyundai customers. Key Contact Information Dealer Support Contact Information Description Parts Techline Warranty HELPREP Line Warranty Prior Approval (PA) Center Xtime Technical Support AutoLoop Technical Support CDK Technical Support Customer Support Hyundai Customer Care Center (Recall /Campaign Questions) Hyundai Recall /Campaign Website Hyundai Customer Care Center (GeneralQuestions) Hyundai Roadside Assistance HyundaiPartsHotline@MobisUSA.com 1-800-545-4515 1‐800‐325‐6604 1‐877‐446‐2922 PA@hmausa.com Support@xtime.com 1‐866‐984‐6355 Support@autoloop.com 1-877-850-2010 https://serviceconnect.support.cdk. com/ Contact Information 1‐855‐671‐3059 www.hyundaiusa.com/recall 1‐800‐633‐5151 1-800-243-7766 Parts ordering hotline Vehicle Technical Support for Hyundai Dealer Technicians Warranty Claim questions for Hyundai Dealers Warranty Prior Approval (PA) Center for Hyundai Dealers Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Assistance with Car Care Scheduling: • Appointment / Shop Capacity Management / Campaign Integration / Operation Codes Description Customer questions or concerns related to recall or service campaigns Updated information related to the specific recall or service campaign Customers general questions, non‐campaign related 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 Car Care Scheduling (Xtime) – Recall Appointment Notification Parts – Campaign Parts Management (CPM) Procedure Service Rental Car (SRC) Program Technical Service Bulletin (TSB) Uncompleted Campaign VIN Listing Recall Campaign Website NHTSAWebsite www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling 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” As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management 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 www.HyundaiDealer.com > Service tab > Hyundai Tech Info A listing of vehicles is located on WEBDCS > SERVICE tab > select UNCOMPLETED CAMPAIGN VIN LISTING – Dealer Stock (New, SRC, CPO, etc.) and Retailed. www.hyundaiusa.com/recall www.safercar.gov Appendix Historical Reference Date • Recall 239: Electric Power Control Unit (EPCU) Leak Inspection and Replacement • Recall 239 Electric Power Control Unit – Remedy Not Available 03/03/2023
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