Hyundai will recall 10,575 Ioniq hybrids and plug-ins 2017 and 2018 due to the potential fire risk. Hyundai previously recalled these models in 2018, but the vehicles in this campaign may not receive the proper overhaul.
Loose connections between the contacts in the main relay can cause an increase in the electrical resistance between them. If this happens, the pieces can heat up and potentially get hot enough to cause a fire. If this problem occurs, the HEV warning light may come on or the vehicle may not start.
The affected Ioniq Hybrid examples have production dates from 16 November 2016, to 16 August 2017. The recalled Ioniq Plug-In Hybrid has an assembly period from 10 August 2017 to 11 August 2017.
Hyundai first became aware of this problem on March 7 2018, when the company received reports of heat damage to the rear seats of the 2017 Kia Niro in the South Korean market. It took until September 2018 for the company to be able to replicate the problem. They found a loose main relay connection and realized that the part had come from an earlier supplier using a lower manufacturing specification. The automaker started an early recall in October 2018.
On June 26, 2021, Hyundai received reports of the 2017 Ioniq burning even after receiving the original recall fix. In November and December 2021, the company received two more reports of its 2017 Ioniqs burning. Both also received a recall fix. By March 2022, the company was aware of two more fires.
Hyundai is investigating the situation. A survey of 11 towed vehicles showed four with improper repairs. The company decided to recall Ioniq. In total, Hyundai has nine reports of this crash occurring from June 26, 2021 to March 6, 2022. There have been no reports of accidents or injuries from this issue in the US.
To fix this problem, the dealer will inspect and replace the main relay and power relay assemblies. The company will begin sending recall notices to affected owners on August 26, 2022. Even vehicles with repairs from the 2018 recall will need to have this new fix.