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 HyundaieBay logo Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 853

 

Summary

HyundaieBay logo Motor America (HyundaieBay logo) 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 HyundaieBay logo customer service at 1-855-371-9460. HyundaieBay logo’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: HyundaieBay logo EV Service Safety series and Kona New Model (SVCH2019OSEVNMTW18_806) web courses on HyundaieBay logo 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 โ€“ Adapter Tool (Pressure Hose/Differential Pressure Hose)
      • KQ366-EV001QQH โ€“ Coolant Discharge Hose 09580-3D100QQH โ€“ 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: โ€œDuring 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 (โ€œEPCUโ€) used in the subject vehicles may have been produced by the supplier with insufficient sealing of the EPCUโ€™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 vehicleโ€™s limited mobility โ€œfail safeโ€ 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 HyundaieBay logo Kona EV vehicles produced from June 18, 2020, through July 31, 2020, by HyundaieBay logo Motor Company (โ€œHMCโ€) 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, HyundaieBay logo 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 โ€œstop saleโ€ 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 HyundaieBay logo 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 HyundaieBay logoโ€™s New Vehicle Limited Warranty.

Additionally, HyundaieBay logo 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

โ–November โ€“ December 2022

On November 2, 2022, HMC informed HMAโ€™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, NASOโ€™s Data Review Committee (โ€œDRCโ€) escalated a new investigation for analysis by the Technical Review Committee (โ€œTRCโ€).  NASOโ€™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 (โ€œNASDAโ€) on December 9, 2022 and decided to conduct a new safety recall of affected model year 2021 HyundaieBay logo Kona EV vehicles in the U.S. to address the defect condition involving the vehiclesโ€™ EPCU.

As of the date of this filing, HyundaieBay logo 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

MAKEMODELYEAR
HYUNDAIeBay logoKONA ELECTRIC2021

 


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

 


Latest Recalls Documents

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

 


 

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