Hyundai issues second recall of Ioniq hybrids over risk of fire

Fountain Valley, CA – July 10, 2022 – Hyundai (NASDAQ:HYMTF) is recalling 10,575 hybrids that may catch fire due to overheating under their rear seats, increasing the risk of crash and injury. 

These vehicles were already repaired due to the same issue in 2018, but are being recalled again on the back of at least 9 fires post-repair. No injuries or crashes have been reported.

Affected vehicles include: 

  • 2017 – 2018 Hyundai Ioniq Hybrid
  • 2017 – 2018 Hyundai Ioniq Plug-In Hybrid

Recall summary  

All hybrid vehicles listed here have a relay, or a switch, which is a part of their electrical system underneath the rear seats. The purpose of the switch is to connect and disconnect “ the battery and the inverter… wiring.

Due to a supplier error, connectors on these relays could be loose. This increases electrical resistance and causes the relay to overheat, which can, in the worst-case scenario, result in  a vehicle fire

The components causing this recall are the power relay and the main relay within it, with part numbers 37514-G2100QQH and 37583-A8000QQH.

Recall risks

An in-vehicle fire that happens while driving or when parked carries several risks. This includes crashes, injuries and property damage. 

Background of the recall

These cars were already recalled over this issue in 2018.

However, starting in 2021, Hyundai began receiving reports of some of the repaired vehicles catching fire. Upon investigating, the manufacturer found that at least some of the vehicles still had original relays in them, despite “repair history displaying” that the relays were switched.

On the heels of that information, the new recall was initiated.

Other Hyundai recalls

Both Hyundai and its subsidiary Kia are subject to a U.S. government investigation over ongoing fire issues. The investigation has so far resulted in 16 recalls, 8 for each manufacturer, according to the federal auto safety regulator, the National Transportation Highway Safety Administration (NHTSA) data.

The regulator is currently evaluating whether the manufacturers will need to recall more cars and whether or not the remedies performed under these recalls were sufficient, as reported.

The repair

Dealers will inspect previously installed relays and replace them if needed. This repair will be free of charge. Notifications will be sent to the owners on August 26, 2022.

Is your vehicle part of this recall?

This Hyundai fire recall is affecting more than 10,000 hybrid vehicles. To do a Hyundai recall check and see if yours is one of them, use MotorSafety’s free vehicle lookup tool.

Bojan PopicHyundai issues second recall of Ioniq hybrids over risk of fire

Hyundai Recalls Over 10,000 Hybrid Vehicles Due to Fire Hazard

Laguna Hills, CA – Hyundai Motor America (Hyundai) is recalling certain 2017-2018 Hyundai Ioniq Hybrid and 2018 Ioniq Plug-In Hybrid vehicles due to an electric defect that causes a fire hazard. The potential number of units affected by this recall is 10,575.

The Defect

According to the NHTSA Recall Safety Report, the subject vehicles contain a Power Relay Assembly (“PRA”) which is located underneath the rear seat. The PRA is equipped with a main relay, which may have been installed too loosely during assembly.

If the PRA operates in this condition, a loose connection between the main power relay contacts could increase electrical resistance. This electrical resistance can generate excessive heat and increase the risk of a fire. Drivers may see illumination of the HEV warning light while driving and/or experience an inability to start their vehicle, which is an indicator of this problem in affected vehicles.

Timeline of Events

On March 7, 2018, HMC received a report indicating that heat damage had occurred on the rear seat of model year 2017 Kia Niro sold in the Korean market. HMC immediately began testing under various driving conditions and maneuvers to determine the cause of the damage, but as of June 2018, was unable to replicate the damage and thus began to focus its investigation on component testing with the supplier.

This testing concluded in August 2018 and again the damage could not be replicated by component bench testing alone. However, HMC conducted additional testing independently, and did manage to replicate the damage on September 18, 2018. Upon inspection of the test vehicle’s damaged rear seat, it was discovered that the damage was caused by increased heat generated by the PRA. The PRA was subsequently examined, and it was discovered that the main relay was loosely connected. This indicated that the heat was the result of increased electrical resistance caused by a loose contact between the main relay terminals.

HMC also noted that the main relay had lower manufacturing specifications for terminal tightening torque and contact pressure, due to being coerced from a former supplier, and that the current supplier was providing main relays which had been produced with higher specifications for terminal tightening torque and contact pressure. The vehicles potentially affected by the former batch of relays was identified via production and supplier delivery records.

All regional distributors of the affected vehicles have informed of these findings, and October 2, 2018, HMC decided to conduct a voluntary safety recall to address the condition in the subject vehicles. Hyundai is unaware of any incidents, crashes, or injuries related to the faulty relays.

The Solution

Hyundai will notify owners, and dealers will inspect the Power Relay Assembly (PRA) for damage. If no damage is found, the main relay will be replaced. If damage is found, the PRA will be replaced. These repairs will be performed free of charge. The recall is expected to begin November 30, 2018. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 178.

Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-704.

Sean ReyesHyundai Recalls Over 10,000 Hybrid Vehicles Due to Fire Hazard