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

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 are expected to be mailed February 14, 2023. 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: 

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.”

 


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.

 


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

 


4 Associated Documents

Recall Acknowledgement

RCAK-22V941-9054.pdf 645.203KB

RCAK-22V941-9054

 


Defect Notice 573 Report

RCLRPT-22V941-1708.PDF 213.801KB

RCLRPT-22V941-1708

 


Attachment A- Chronology

RMISC-22V941-8449.pdf 98.631KB

RMISC-22V941-8449

 


Manufacturer Notices(to Dealers,etc)

RCMN-22V941-5318.pdf 274.431KB

RCMN-22V941-5318

 


Latest Recalls Documents

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

 


 

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