ICCU recall (large scale)

electriceddy

electriceddy

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Expected to include E-GMP 500,000 vehicles worldwide.
Hyundai, Kia to Make Largest EV Recall since Launch of First EV Models - Businesskorea

"It is the largest voluntary recall in three years since the automaker entered the market...

An ICCU is responsible for managing electric vehicles’ power and controlling batteries. If there is a problem with an ICCU, the electric car may not start, its battery may be discharged, and it may not be possible to fully charge the battery. In the meantime, there have been many reports of ICCU failures in Korean electric cars among members of internet car communities in Korea.
A separate investigation was underway in the United States regarding the recall. The US National Highway Traffic Safety Administration (NHTSA) conducted its own investigation following a complaint that the IONIQ 5 loses power while running. “It was determined that the power loss was caused by the ICCU,” the NHTSA said in its preliminary report on the case, “We found that the transistor could be damaged due to overcurrent within the ICCU.” Hyundai Motor Group’s decision to recall the models is likely a proactive move ahead of regulatory decisions in North America and Europe, some experts say."

Hopefully materials required to complete the task at hand will be available within too long.
I can see this progressing on a need to replace basis, more or less like the recent worldwide pack recall LG - Kona and Bolt EVs.
It is a good thing in any case, and hopefully solves the well-documented issue at hand for existing owners.:)
I would expect the problem component(s) will be upgraded in all ICCU's going forward ie: 2025 MY.
 
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Yep.
This hit here in the US.
My I6 is going in tomorrow for the update and hardware check.
Similar to the same one sent out last year for the same issue….except different update this time.
Hope they finally get it right with this one!
 
rcarter3636 said:
Software update and fuse replacement complete.
ICCU checked out ok.
Took about 45 minutes.
Click to expand...
If DTC P1A9096 is stored, than ICCU must also be replaced, if no DTC is stored, than a software update is only required...at least according to this March 2024 recall TSB:
HMA TSB (nhtsa.gov)
"It is critical when performing repairs to ensure the ICCU and High Voltage Fuse are replaced simultaneously. Damage to the PRA can occur if the High Voltage Fuse is replaced and the vehicle is placed in "Ready Mode" without the replacement ICCU part."
If the repair only took 45 minutes, I suspect software updated only. The allowance time for ICCU replacement, software and coolant replacement is 2.1 to 2.4 M/H
At least the way I read it, only fuse replacement and software update if the ICCU has been replaced.
 
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electriceddy said:
If DTC P1A9096 is stored, than ICCU must also be replaced, if no DTC is stored, than a software update is only required...at least according to this March 2024 recall TSB:
HMA TSB (nhtsa.gov)
"It is critical when performing repairs to ensure the ICCU and High Voltage Fuse are replaced simultaneously. Damage to the PRA can occur if the High Voltage Fuse is replaced and the vehicle is placed in "Ready Mode" without the replacement ICCU part."
If the repair only took 45 minutes, I suspect software updated only. The allowance time for ICCU replacement, software and coolant replacement is 2.1 to 2.4 M/H
Click to expand...

Maybe so.
It read:
DTC Chk ICCU & ICCU Fuse RPL (24-01-023H)DTC
Software update (recall 257)WII ZZ3
 
Had my 2023 Ioniq 5 serviced yesterday for my one year service and this recall. Says: "iccu inspected, no codes, update complete"
 
I had the ICCU recall done soon after it was announced last spring. The dealer service notes read “ICCU inspected, no codes, update complete.” It took about a half hour, so I’m sure nothing was replaced and just the software was updated. Last evening, after use of the car during the day, I went out to the garage to plug in the EVSE and found a completely dead Ioniq 5 with no electrical power. No doors were left open and nothing was left on. The traction battery is at about 65% charge, as I recall. I could probably bring it back to life with the NOCO jump pack I always carry, but I’m going to wait until Monday and see what the dealer wants me to do. I checked voltage of the 12v battery and it was dead at 3.31v, so I’m not sure it’s ok to drive. I know the traction battery can supply 12v through the DC-DC converter, but if the ICCU and 12v battery have failed, I might not make it 10 miles to the dealer? Another owner I know has had 2 ICCU replacements. I’m disappointed, to say the least, that the recall fix doesn’t work. I hope Hyundai handles this for me better than they did when my tire mobility kit leaked all over the trunk. That took 5 months of hassle. :eek:
 
Sandroad said:
I had the ICCU recall done soon after it was announced last spring. The dealer service notes read “ICCU inspected, no codes, update complete.” It took about a half hour, so I’m sure nothing was replaced and just the software was updated. Last evening, after use of the car during the day, I went out to the garage to plug in the EVSE and found a completely dead Ioniq 5 with no electrical power. No doors were left open and nothing was left on. The traction battery is at about 65% charge, as I recall. I could probably bring it back to life with the NOCO jump pack I always carry, but I’m going to wait until Monday and see what the dealer wants me to do. I checked voltage of the 12v battery and it was dead at 3.31v, so I’m not sure it’s ok to drive. I know the traction battery can supply 12v through the DC-DC converter, but if the ICCU and 12v battery have failed, I might not make it 10 miles to the dealer? Another owner I know has had 2 ICCU replacements. I’m disappointed, to say the least, that the recall fix doesn’t work. I hope Hyundai handles this for me better than they did when my tire mobility kit leaked all over the trunk. That took 5 months of hassle. :eek:
Click to expand...
Your Ioniq 5 is sad it can't be as faithful as your Honda Clarity was :)

upload_2024-10-12_20-48-21.webp
 
Quick update on my post 7 above…..the dealer wanted the car towed to them, so I called Hyundai Roadside Assistance. The guy who came out had no idea what an EV was. I had to figure out how to jump start the car with my other car (he had no jumper cables) to release the electric parking brake and I had to back the car onto his truck because he wouldn’t drive an EV. He was lucky I even knew where the battery is. My NOCO GB20 jump pack would have worked too, but my other car with jumper cables was right there and just as convenient. After it got to the dealer, they told me I should have just replaced the 12v battery, but I said I wanted them to check codes and see why it failed. The kicker in the whole thing is the service department can’t even look at it until Oct 29 and they offered no loaner. So hopefully sometime next month I can provide an update.

In the meantime, I highly recommend Ioniq 5 owners know where the 12v battery is and carry a jump pack in the frunk (not the rear cargo trunk). When the 12v battery dies, the brakes are locked and nothing works.

And yes, @insightman, the Clarity and the Honda dealer is much missed right now.
 
Sandroad said:
Quick update on my post 7 above…..the dealer wanted the car towed to them, so I called Hyundai Roadside Assistance. The guy who came out had no idea what an EV was. I had to figure out how to jump start the car with my other car (he had no jumper cables) to release the electric parking brake and I had to back the car onto his truck because he wouldn’t drive an EV. He was lucky I even knew where the battery is. My NOCO GB20 jump pack would have worked too, but my other car with jumper cables was right there and just as convenient. After it got to the dealer, they told me I should have just replaced the 12v battery, but I said I wanted them to check codes and see why it failed. The kicker in the whole thing is the service department can’t even look at it until Oct 29 and they offered no loaner. So hopefully sometime next month I can provide an update.

In the meantime, I highly recommend Ioniq 5 owners know where the 12v battery is and carry a jump pack in the frunk (not the rear cargo trunk). When the 12v battery dies, the brakes are locked and nothing works.

And yes, @insightman, the Clarity and the Honda dealer is much missed right now.
Click to expand...
I'm glad you didn't take my attempt at a funny photo the wrong way in your hour of stress and disappointment.

It's unhelpful the service department told you you should have changed the battery yourself, but it's unacceptable the service department can't take a moment to pull codes from an I5 that up and died. The earlier the diagnosis, the quicker the fix (hopefully).

Since the I5 was first revealed, I've liked its look (except for the missing rear wiper just added for 2025), but I am disappointed when I read online about Hyundai service department failures--especially the delays.
 
@Sandroad Sorry to hear you have been having so much trouble with your local Hyundai service department. It is a shame that they would be so unprepared to service a model that has been out for 3 years now.

I had my Ioniq 5 serviced for both the ICCU and the tire mobility kit (which thankfully had not leaked yet) at the same time a few months ago. The ICCU ended up just being the software update and I only had to wait two days for the replacement kit (I just drove back a few days later to pick it up). I invested in a jump pack and store it in the frunk in case the 12V battery dies. Hopefully having the jump pack that close to the 12V battery will scare the 12V into behaving! ;)

[EDIT] Question for the audience - what is the term to explain the last sentence above? The concept of "Carrying an umbrella will keep it from raining" has a term, right? I thought it was "Sod's Law" but after looking it up that doesn't apply. I seem to remember a term for it, but "preparedness paradox" is the closest I could find but is not quite right.
 
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Christopher Beer said:
what is the term to explain the last sentence above? The concept of "Carrying an umbrella will keep it from raining" has a term, right?
Click to expand...
I suspect there's a better answer than the one Google Search Labs' came up with. Does "prophylactic measure" ring a bell with you?

A phrase like "carry an umbrella to keep it from raining" is called a prophylactic measure; it refers to an action taken to prevent a potential problem, even if it seems unnecessary at the time.
 
insightman said:
I suspect there's a better answer than the one Google Search Labs' came up with. Does "prophylactic measure" ring a bell with you?

A phrase like "carry an umbrella to keep it from raining" is called a prophylactic measure; it refers to an action taken to prevent a potential problem, even if it seems unnecessary at the time.
Click to expand...

"prophylactic measure" isn't accurate for the umbrella/rain situation. According to the definition you provided (and the Merriam-Webster definition), "prophylactic measure" applies when the action you take actually impacts the result. In the case of the umbrella/rain quote, a person can't really change the weather by carrying an umbrella (unless your belief system is wildly divergent from mine). Claiming that it does is an obvious fallacy, but one which a lot of people like to humorously propagate. Terms like "self-fulfilling prophecy" (or would it be "self-defeating prophecy" in this case?) and "prophylactic measure" apply when the action taken impacts the outcome.

I don't really expect that having a jump pack in my car will "scare" the 12V battery into doing anything. But people will know that I am making the joke because that type of statement is a well know humor trope. I was going to tag that sentence for added effect, like you often see when people tag sarcastic content like "<sarcastic>The new VW ID Buzz is a great value!</sarcastic>", but I couldn't think of the term for that type of statement. Maybe I should call it a fallacy, because "a fallacy is reasoning that comes to a conclusion without the evidence to support it." (Merriam-Webster again)? But that feels wrong since "fallacy" feels more like someone making invalid arguments rather then ridiculous ones. I feel like there should be a more specific term for this type of statement where its obvious that the reasoning is wrong.
 
To recap and summarize,

Last April, we received the recall on our 2023 SEL AWD for the potential Integrated Charge Control Unit failure with its ominous warnings about the vehicle dying on the highway if the ICCU failed. The service department tested the ICCU and its fuse and found it passed the tests, so it was updated but nothing was replaced. In August, we received the Service Campaign for the level 2 charging problem and the service department applied the update. Otherwise, the car has had all factory recommended service at the dealership, including replacing the leaky Tire Mobility Kit (after a 4 month wait).

We met some local folks in September who have the same year/make/model as our car and they told us they had to have the ICCU replaced twice, each time requiring a long tow with a dead car. They had some other issues with their car and attempted to have Hyundai buy it back, but were refused. I do know of another owner who did have Hyundai buy his Ioniq 5 back due to electrical issues.

On Friday October 11, we drove our car normally and routinely during the day for our usual local trips. In the evening when I went out to the garage to charge it from 60%-80%, I found the car electrically dead, with nothing working. No doors had been left open and no lights had been left on. The following Monday on 10/14, the dealer service department told us to call Hyundai Assurance Roadside Assistance and have the car towed to them. When it arrived at the dealer the service writer said it would be more than 2 weeks before it could even be looked at, unless someone else cancelled their appointment in the meantime. No loaner was provided.

Hyundai Assurance Roadside Assistance was ATROCIOUS and insult to injury in our situation. The tow truck driver sent out was incompetent to say the least. First, he said company policy prevented him from entering the garage to retrieve the car. Second, he had no idea how to move an electrically dead EV with its parking brake locked on. I had to figure out how to apply enough temporary 12V power to release the brake and move it outside. Third, he refused to put an EV onto his truck himself (or help), so I had to figure out how to get the car on the truck. After I got it on there, I found it’s tricky for a senior like me to jump off tow trucks with the bed tipped.

When the service department eventually called my wife to come pick up the car, she was told no diagnostics could be done because the electrical failure had erased all trouble codes. Therefore they had no idea what caused the failure. The 12V battery was damaged beyond recharge ability, so it was replaced.

With: 1) the electrical failure in our car, 2) the lack of any information about what caused the failure, 3) our previous knowledge of the ICCU recall, 4) known recurrent ICCU/electrical failures in other cars, and 5) the hassles and dangers of having a dead car towed by Hyundai Assurance Roadside Assistance, especially if the car fails on the highway and shuts down, we began to seriously wonder about future reliability.

We knew from experience neither the dealer nor Hyundai would be able or willing to help with reliability. All things considered, my wife said enough is enough and we just now traded it in on a Toyota RAV4 Prime.
 
We have a UK version 2024 MY IONIQ5 Ultimate AWD 10000 miles since June 2024. I broke down with the 12v failure in early January and has been at the dealers since then (5 weeks) awaiting the ICCU part which is on back order with no ETA - no spares in the UK apparently. Frustrating to say the least - is this a common problem in the UK and has the MY 2025 had the problem fixed? Thank you
 
A very short video (43 seconds) showing ICCU replacement and related fuse:

Would hate to be the technician who drops the nuts into the battery compartment by mistake:oops:
 
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