Hyundai Ioniq Power Relay Could Overheat And Cause A Fire

On 2022-07-13 12:50:12

Hyundai Motors (Hyundai) will be contacting the owners of certain 2017-2018 Ioniq Hybrid Electric Vehicles (HEVs)  and  2017-2018 Ioniq Plug-In Hybrid Vehicles (PHVs), for a problem affecting the Power Relay Assembly (PRA) located underneath the rear seat of their cars.  This problem affects the same 2017-2018 Ioniq vehicles recalled under the NHTSA campaign number 18V-704.  These vehicles will need to be repaired again.

In March 2018 Hyundai received their first report of heat damage on the rear seat of a 2017 Kia Ioniq.  They immediately began testing to determine the cause of the problem and found it came from an increase in heat generated by the power relay assembly.  Further inspection found that the main relay had a loose connection and the heat was likely caused by increased electrical resistance at the contact between the main relay terminals.  A review of the manufacturing reports showed that the main relay came from a previous supplier that used lower torque specifications for terminal tightening and contact pressure.  In October 2018, Hyundai issued recall 18V-704 to fix the problem.

In June 2021, Hyundai continued to receive reports of vehicles that caught fire after reviving the recall.  Hyundai has identified nine (9) reports of the condition in the vehicle population after receiving the recall fix.  According to the defect report, certain 2017-2018 Ioniq vehicles recalled under the NHTSA campaign number 18V-704, may not have received the proper remedy components.  If the vehicle continues to operate in this condition, an increase in electrical resistance could result in a vehicle fire.

Dealers will inspect and replace the power relay as necessary. This recall replaces NHTSA recall number 18V-704. Vehicles already repaired under the previous recall will need to have the new remedy completed.   Hyundai's number for this recall is 232 and the NHTSA campaign number is 22V-495.