Recall 252 – Engine Compartment Fire from Short Circuit – 2024 Hyundai Kona

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December 26, 2023 NHTSA CAMPAIGN NUMBER: 23V901000

Engine Compartment Fire from Short Circuit

A short circuit increases the risk of an engine compartment fire.

 

NHTSA Campaign Number: 23V901

Manufacturer Hyundai Motor America

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 10,984

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2024 Kona vehicles. The 12-Volt battery cables may chafe against the engine control module bracket and short circuit during a crash.

 

Remedy

Dealers will install sheathing over the wiring, free of charge. Owner notification letters are expected to be mailed February 23, 2024. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 252.

 

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

Certain 2024MY Kona (SX2) vehicles equipped with a 1.6T engine contain a 12-volt positive battery cable that could become damaged during a frontal crash by contacting the vehicle’s engine control module bracket. An electrical short from the damaged 12-volt positive battery cable to bracket contact increases the risk of a postcrash engine compartment fire.

 

Applicable Vehicles (Certain)

  • 2024MY Kona (SX2) equipped with 1.6T engines produced 06/19/2023 – 11/27/2023 for sale in the U.S.

 

Remedy Information

The procedure provided in TSB 23-01-095H (or latest version) provides the recall’s service procedure to install crush shields (protective sheathing) on the 12-volt battery wiring in the engine room junction block.

  • Recommended Service Technician Training Level: Hyundai Certified or higher

 

Service Tips/Training

  • If a customer arrives to the dealer with no appointment scheduled, it is recommended for the dealer to offer alternative transportation to the customer while part(s) are ordered.
  • If customer schedules an appointment in advance, order the parts ahead of time to prevent any delays; this recall service procedure is 100% installation.
  • Always inquire if the customer will have time for an additional service to be performed if they were originally scheduled for a different service.
  • Offer SRC assistance for customers who may be pressed on time.
  • Be honest with customers on wait times.
  • If the service is taking longer than expected, update the customer.
  • If you are unsure of certain processes, don’t guess. Take time to familiarize yourself with the proper procedures or ask for help/clarity from your teammates or leadership.
  • If you see a team member having trouble addressing the concern, ask if you can provide some help.

 

Recommended Alternative Transportation

A Service Rental Vehicle (SRC) should be provided to customers who do not feel safe operating their vehicle until the remedy is complete. In addition, a SRC may be required based on any other additional work on the vehicle that may need to be addressed during customer’s visit. If a SRC is not available, other options such as a 3rd Party Rental or Rideshare may be provided.

 

Required Supplies

  • Dealers will require black PVC electrical tape on-hand to complete the repair.
  • Ensure this tape is used to tightly wrap the installed crush shields.
  • Dealers will be reimbursed in sublet on the claim for use of the tape.

 

Sample Customer Talk Track

  1. For customer with an appointment, but recall not part of the originally scheduled services: “I see that your vehicle has an open recall campaign that we would like to take care of for you while you are here today. This Recall Campaign 252 relates to the electrical system where the 12-volt positive battery cable can may come into contact another bracket from the engine control module, potentially causing an electrical short. In the event of a crash, an electrical short resulting from the contact may increase the risk of a post-crash engine compartment fire. We will repair your vehicle to prevent this from occurring by installing protective sheathing on the 12-volt battery cables. This service, of course, will be provided at no charge to you. If necessary, we would like to offer you an SRC while we repair your vehicle. We apologize for the severe inconvenience.” 
  1. For Walk-in Customer: “During your visit today, I checked your vehicle for any open campaigns or recalls and found that your vehicle has an open recall with an available remedy. The recall states that it is a condition relating to the electrical system, involving the vehicle’s 12-volt positive battery cable. The recall’s remedy is to install protective sheathing on the 12-volt battery wiring cables. This service, of course, will be provided at no charge to you. We apologize for the severe inconvenience.” 
  1. For customers over the phone: “While I have you on the line and verifying your current appointment, I ran your VIN and see that your vehicle has an open recall that relates to the vehicle’s electrical system, involving the 12-volt positive battery cable. The recall’s remedy is to install protective sheathing on the 12volt battery wiring cables. If time permits, we can address this recall during your current appointment and it will be at no cost to you. Should you need transportation assistance during this time, we can help arrange an SRC since this may prolong the stay of your vehicle at service. We apologize for the inconvenience.”

 

Customer FAQ

Q1: What is the issue?

A1: The subject vehicles contain a 12-volt positive battery cable(s) that could become damaged during a frontal crash due to contact made with the vehicle’s engine control module (“ECM”) bracket, potentially causing an electrical short.

 

Q2: What are the affected vehicles?

A2: Affected vehicles include certain model year 2024 Hyundai Kona vehicles equipped with 1.6-liter turbocharged engines and produced 06/19/2023 – 11/27/2023 by Hyundai Motor Company (“HMC”) for sale in the U.S. market.

 

Q3: What is the safety concern?

A3: An electrical short from the damaged 12-volt positive battery cable(s) to bracket contact increases the risk of a post-crash engine compartment fire.

 

Q4: Have there been any accidents or injuries?

A4: As of the filing to NHTSA on 12/26/2023, there are no crashes, injuries, or fatalities attributable to this condition in both the U.S. and Canada. Hyundai has confirmed one (1) fire occurring in an IIHS (Insurance Institute for Highway Safety) test vehicle. There are no known fire events occurring on retailed vehicles in the field due to this condition.

 

Q5: Will a Dealer Stop Sale be issued?

A5: Yes, a Dealer “Stop Sale” (hold) has been issued in accordance with federal regulation for involved vehicles unsold at dealers. In addition, a Port “hold” has been issued for all involved vehicles located at ports and vehicle processing centers.

 

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

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 install protective sheathing over the 12-volt positive (B+) and alternator wiring connected to the junction block located in the engine compartment.

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.

 

Q7: When will owners be notified?

A7: Owners of the subject vehicles will be notified via First Class mail in late February 2024.

 


NUMBER
23-01-095H

DATE
DECEMBER 2023

ENGINE ROOM JUNCTION BLOCK WIRING – CRUSH SHIELD INSTALLATION (RECALL 252)

Description: Certain 2024MY Kona (SX2) vehicles equipped with a 1.6T engine contain a 12-volt positive battery cable that could become damaged during a frontal crash by contacting the vehicle’s engine control module bracket. An electrical short from the damaged 12-volt positive battery cable to bracket contact increases the risk of a post-crash, engine compartment fire. Follow the procedure in this TSB to install crush shields on the 12-volt battery wiring in the engine room junction block to reduce the risk of an electrical short or fire.

 

Applicable Vehicles (Certain):

  • 2024MY Kona (SX2) equipped with 1.6T engines produced 06/19/2023 – 11/27/2023

 

Service Procedure:

Refer to the Information In PDF below…

 

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RECALL 252 ATTACHMENT A
CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

❖ November 2023
On November 21, 2023, HMA’s NASO was notified by the Insurance Institute for Highway Safety (“IIHS”) of an engine compartment fire that occurred on a model year 2024 Hyundai Kona 1.6T-GDI AWD test vehicle during a 40% frontal overlap evaluation performed at approximately 40 mph. According to the IIHS, smoke and flames were observed from the vehicle’s engine compartment approximately two (2) minutes following the crash test. IIHS performed a preliminary evaluation and found the ECM housing shorted to power and rising in temperature, reigniting flames two (2) additional instances after the initial fire. IIHS claimed that the thermal activity ceased shortly after disconnecting the 12-volt auxiliary battery. Based on this information, NASO opened a new investigation for the subject condition on November 27, 2023.

On November 29, 2023, NASO, along with members from HMC, HATCI, and IIHS, performed a joint inspection and tear-down of the test vehicle. During the inspection, the alternator and 12-volt positive (B+) power wiring located underneath the ECM was found damaged due to heat with the copper cores exposed. Additionally, the ECM bracket was found pushed directly into the 12-volt positive (B+) battery cable. Hyundai concluded that the ECM bracket shifted during the crash, contacting the 12-volt positive wiring, and causing an electrical short leading to the post-crash fires observed by IIHS. Hyundai continued investigating the condition observed during the inspection.

❖ December 2023
On December 8, 2023, NASO and IIHS performed a follow-up joint inspection of the subject test vehicle at IIHS facilities.
On December 14, 2023, HMC performed crash testing using new sheathing aimed at safeguarding the 12-volt positive wiring from electrical shorting caused by the ECM bracket. The crash test was performed successfully and confirmed no damage to the 12-volt positive wiring and no evidence of electrical shorting or thermal activity.

Based on HMC’s findings, HMA’s NASO convened its North America Safety Decision Authority on December 18, 2023, and decided to conduct a safety recall of affected Hyundai Kona vehicles in the U.S. market.

❖ There are no crashes, injuries, or fatalities attributable to this condition in both the U.S. and Canada. Hyundai has confirmed one (1) fire occurring in the IIHS test vehicle. There are no known fire events occurring on retailed vehicles in the field due to this condition.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
HYUNDAI KONA 2024

 


5 Associated Documents

Recall Acknowledgement

RCAK-23V901-3586.pdf 645.347KB

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Defect Notice 573 Report

RCLRPT-23V901-8581.PDF 213.928KB

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Attachment A – Chronology Report

RMISC-23V901-1123.pdf 107.864KB

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Remedy Instructions and TSB

RCRIT-23V901-9924.pdf 1418.457KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V901-4525.pdf 428.765KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V901&docType=RCL

 


 

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