Help! Charging door won't open!

Discussion in 'Hyundai Kona Electric' started by Bruce M., Mar 18, 2023.

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  1. Bruce M.

    Bruce M. Active Member

    I just went to plug in my Kona to top it off before going for a drive in a little while, and the charging door won't open. I've tried it maybe 15 times, being sure to press the "unlock" button, etc., but when I press the charging door to open it, it won't come open. My local Hyundai dealer's service department isn't open till Monday, and I had stuff I wanted to do this weekend -- and don't like driving my battery down to near zero. Anyone got any ideas????
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  3. tjkvt

    tjkvt New Member

    I assume you have checked, but make sure your car is unlocked and in Park. I had this same issue once and discovered that the car doors were locked even though I had not locked them.
  4. Bruce M.

    Bruce M. Active Member

    Yes. I've checked it enough times I should probably see a psychiatrist.
  5. Bruce M.

    Bruce M. Active Member

    Sigh... I belatedly noticed there's an older thread about this same issue. Alas, I tried the suggestions offered there, which apparently worked for some people, with no luck. I guess I just have to get it to the dealer ASAP. Damn.
    electriceddy likes this.
  6. hieronymous

    hieronymous Active Member

    Last edited: Mar 18, 2023
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  8. I think this is a weakness of the design. Water and dirt can enter around the plunger. I'm not sure if it helps but I've cut a washer out of closed-cell foam and placed it inside the pocket as a gasket of sorts. It's the type of foam that is grey, very light and looks recycled.
  9. Bruce M.

    Bruce M. Active Member

    Hmmm... well if I can get the charging door open (more accurately, when the dealer gets the door open), we'll see if dirt or something got in there. For now I'm stuck keeping my driving to a minimum till I can get to the dealer, hopefully Monday.
  10. Agreed a design issue, which is why I keep my pack charged at least 50% when possible. I will be working on a "modification" this summer to allow a mechanical release, it may involve removing one wing on the plunger latch itself or catch adjustment.
    Where there any warning signs (stiff door or missed catch previous) ...or did it just refuse to open?
  11. Bruce M.

    Bruce M. Active Member

    Yes, like you I rarely let my battery go below 50% except on long drives when I can't avoid it. So I can do essential driving for a couple days, but the recreational drive I was going to do today got scrubbed. I didn't perceive any signs of trouble. I worked perfectly normally right through the last time I charged, which was probably 4 days ago. Then, this morning, it just wouldn't open.
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  13. Well on the bright side, travel time for replacement parts should be cut in half, due to your location. (Theoretically but maybe not logistically)
  14. I had this issue on the 2018 build Kona. Eventually I thumped the door really hard after going through the lock/unlock routine. The door opened. Now it latches shut but does not lock any more and I’m not going to get it fixed.

    Sent from my iPhone using Inside EVs
    electriceddy likes this.
  15. I had this problem about a year ago. In my case, I managed to get it to release eventually by repeatedly locking and unlocking the car while pressing on the charge door each time. I then gave it a good charge.
    The problem reoccurred after a few days and I booked it into the dealer for a warranty repair which required a parts order and it has been OK since.
    electriceddy likes this.
  16. Wish you included the video, beats any TSB I have heard of so far:D
    John Lumsden likes this.
  17. Ideas here:

    Technical Service Bulletin
    TSB 20-BD-002H Body January, 2020 Kona Electric (OS EV)
    Description: This bulletin describes the procedure to repair certain Kona Electric (OS EV) vehicles which may experience difficulty with opening the charging door.
    ... Service Procedure: 1. Open the charging door cover (A). :( ...

    Good luck
  18. Bruce M.

    Bruce M. Active Member

    All the various suggested tricks -- banging on the door, locking and unlocking, etc. -- haven't worked. It goes to the dealer tomorrow. Here's a question: The car is just over 3 years old. Will they cover it under warranty as part of the electric vehicle system? It sure seems like they should, but I fear they won't.
    electriceddy likes this.
  19. Tomek

    Tomek Active Member

    Powdered water. Preparation method: open a bag of powdered water and pour it into a glass. Dilute with water, stirring constantly. ;-)
  20. insightman

    insightman Well-Known Member Subscriber

    What did the dealer's service department say about warranty coverage when you made the appointment? They probably said, "It depends," right?

    I'll guess you'll be willing to pay if they won't cover the cost of the repair because that's the only way you can keep driving. If they can blame you, then it won't be covered--did you damage the door trying to get it open?

    The next step is to read the warranty. The step after that is to decide if this problem worth hiring a lawyer to help interpret the warranty, hoping the warranty doesn't say a broken charging port door isn't covered.

    If my EV wouldn't let me open the charging port door, I'd be willing to pay significant money if they could install a manual release option. Alternatively, will they let you watch and record how they get the charging port door open?

    The lack of a manual release makes it seem that no one at Hyundai saw this problem as a possibility.
    electriceddy likes this.
  21. You are correct in assuming it is covered as part of the EV System Warranty as it is a part of the Onboard charger connector (as listed).
    In Canada the duration is 96 Months or 160,000 km. I am sure the U.S. has an equivalent duration.;)
  22. Bruce M.

    Bruce M. Active Member

    I am on my way to the dealer for the repair momentarily. Let us hope they don't try to screw with me on this (I have no faith in car dealers)
  23. As stated above, and if no warranty clip the wings off the plunger and use velcro to hold the charge port door from inside. All you will have to pay is the disassembly labor, but I feel it won't have to go that far.
    If they do allow you to observe and record, please post the details and results...good luck.
    Last edited: Mar 21, 2023
    insightman likes this.

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