Hyundai Kona/Ioniq38 battery replacement

slave1 · 25-02-2021 11:19am #1

Official worldwide replacement now so rather than get buried in various threads thought it would be an idea for a single thread so folk can share as the recall progresses....

BigAl81 · 26-02-2021 11:02am

Eek!

RTE are reporting on this yesterday here.

"Kona and Ioniq owners are advised to limit battery charging to 90% of capacity until the battery has been replaced, Hyundai's parent company said."

No word from Hyundai Ireland letting people know that! I've pinged them on Twitter and on their chat on Hyundai.ie with the following message...

"RTE reporting yesterday not to charge Kona's and some Ioniq's past 90% due to fire risk. Have heard nothing from Hyundai on this, can you confirm please? Also, will there be a battery recall / replacement in Ireland? "

I'll let you know if I hear back.

Al.

26-02-2021 11:38am

Will the Kona replace the Zafria B as the butt of all fire jokes?

Mickeroo · 26-02-2021 12:26pm

BrownFinger wrote: »

Will the Kona replace the Zafria B as the butt of all fire jokes?

I think one of them will have to burn down a few buildings here before that happens :pac:

BigAl81 · 26-02-2021 4:06pm

To be fair, Hyundai replied quickly. However it's a nonsense / PR answer.

"Many thanks for getting in touch. The situation for models sold in Europe is being investigated. To date, Hyundai is not aware of any crashes or fires in Europe confirmed to be directly attributable to this condition."

They say "we are not aware" of issues in Europe, not that there are no issues. They also completely ignored my question about limiting charging to 90% as per the RTE article.

Al.

KCross · 26-02-2021 10:39pm

Blame game still in progress....
https://insideevs.com/news/490950/lg-energy-solution-suspected-cause-kona-fires/

Seems it’s not the initially reported separator issue anyway.

A manufacturing error on the anode and a badly programmed BMS are mentioned. I don’t think either side will admit fault as they’d have to take all the cost on board.

27-02-2021 10:33am

Father's Kona has twice had to be towed off driveway after a full charge. Last time they said that they'd fixed it - no problems since, but should I be advising him to keep an eye on the charging and not leave it go above 90%? Seems to be conflicting suggestions in many places.

Old diesel · 27-02-2021 11:49am

[Deleted User] wrote: »

Father's Kona has twice had to be towed off driveway after a full charge. Last time they said that they'd fixed it - no problems since, but should I be advising him to keep an eye on the charging and not leave it go above 90%? Seems to be conflicting suggestions in many places.

Imo charging to only 90 percent is a good idea as a precaution.

Still have plenty of range at that level of charge

Smee_Again · 27-02-2021 11:51am

Deleted User wrote: »

Father's Kona has twice had to be towed off driveway after a full charge. Last time they said that they'd fixed it - no problems since, but should I be advising him to keep an eye on the charging and not leave it go above 90%? Seems to be conflicting suggestions in many places.

I've already set mine to stop at 90%, why take the risk and it's not like I've anywhere to go that I'd miss the the additional c. 45KM.

zg3409 · 27-02-2021 1:30pm

On Facebook there is a chart saying manufacturing dates of the following European destined cars will be affected:

Kona May 2018 to March 2020
Ioniq38 June 2019 to January 2020

UK/Irish models might be different dates due to different side steering wheel.
Take all this with a pinch of salt. Presumably they will notify owners at some stage.

KCross · 27-02-2021 1:56pm

Kramer wrote: »

Plus didn't they recall Konas recently, to address an issue with the BMS? Probably trying to nerf the packs in some way, to minimise the possibility of fire.

Just like Tesla, tinkering with their owners' MCUs, to get out of footing the bill for a massive, forced recall.

What's his name in Australia, Kadoggin is it, on Youtube, is gonna have a ball with this news .

eagerv wrote: »

Yes, it will be interesting, seeing he owns one..

He wasnt too harsh on them!

Old diesel · 27-02-2021 4:06pm

Would be interesting to know (if confirmed) why theres early 2020 cut off dates.

Was there changes in production at that point????

fricatus · 27-02-2021 6:59pm

KCross wrote: »

He wasnt too harsh on them!

Imagine if it had been Tesla though? He’d have been salivating!

liamog · 27-02-2021 7:14pm

Old diesel wrote: »

Would be interesting to know (if confirmed) why theres early 2020 cut off dates.

Was there changes in production at that point????

If it is a problem with the cell separator in the battery cell, then it's likely that LG have made changes to the manufacturing process.

innrain · 27-02-2021 7:39pm

I'm wondering how long it will take for the replacement to happen. You don't sit on 5GWh batteries on the shelf waiting.

eagerv · 27-02-2021 7:56pm

I wonder whether they might offer a buy-back scheme?

Old diesel · 27-02-2021 8:20pm

liamog wrote: »

If it is a problem with the cell separator in the battery cell, then it's likely that LG have made changes to the manufacturing process.

Thats my thinking too.

But confirmation that changes are made would be useful reassurance to customers.

Black_Knight · 27-02-2021 8:52pm

Seemingly is for ioniqs manufactured between June 2019 and Jan 2020 in Europe.

Konas between may 2018 and march 2020. At least that's what I interpret from the post on Facebook allegedly from a Hyundai recall presentation.

Black_Knight · 27-02-2021 8:53pm

See image attached

27-02-2021 8:58pm

a discounted upgrade to something desirable like an Ioniq 5 would be welcomed. VW did that for dieselgate.

zg3409 · 28-02-2021 12:45pm

zg3409 wrote: »

On Facebook there is a chart saying manufacturing dates of the following European destined cars will be affected:

Kona May 2018 to March 2020
Ioniq38 June 2019 to January 2020

UK/Irish models might be different dates due to different side steering wheel.
Take all this with a pinch of salt. Presumably they will notify owners at some stage.

Link to official Hyundai website confirming numbers and dates

https://www.hyundai.com/content/hyundai/ww/data/ir/calendar/2021/0000000310/files/21-02-24-kona-ev-recall-presentation.pdf

zg3409 · 05-03-2021 4:29pm

https://insideevs.com/news/492387/hyundai-confirms-kona-electric-fires-cause/

Hyundai Officially Confirms Folded Anode Tab Caused For Kona EV Fires

Miscreant · 05-03-2021 5:19pm

zg3409 wrote: »

Link to official Hyundai website confirming numbers and dates

https://www.hyundai.com/content/hyundai/ww/data/ir/calendar/2021/0000000310/files/21-02-24-kona-ev-recall-presentation.pdf/

Am I reading that correctly? Estimated cost of 1Tr KRW? 1 Trillion Korean Won... That is a 1 with 12 zeros after it! Over €740 million then which sounds like a lot considering the lion's share of that are Kona and Ioniq vehicles. The busses only account for 305 of the total (less than 0.4%). Averaging that out across all the vehicles in the recall, I doubt they are looking at a buy back scheme as it only allocates just over €9000 equivalent each...

It isn't going to bring Hyundai down but wow, the mind boggles. Next question is though, who has the manufacturing capacity to build these new batteries and will it affect the further rollout of EVs in Hyundai's stable.

I suppose it all remains to be seen.

slave1 · 05-03-2021 5:25pm

Miscreant wrote: »

It isn't going to bring Hyundai down but wow, the mind boggles. Next question is though, who has the manufacturing capacity to build these new batteries and will it affect the further rollout of EVs in Hyundai's stable.

That's it exactly, the real cost, they will have to give battery priority to replacement packs so new cars will suffer big time.

Next issue, what will they do with all the battery packs they take back????

KCross · 05-03-2021 6:48pm

zg3409 wrote: »

https://insideevs.com/news/492387/hyundai-confirms-kona-electric-fires-cause/

Hyundai Officially Confirms Folded Anode Tab Caused For Kona EV Fires

That article is a bit misleading as it says its all LG's fault.
I believe there is accepted responsibility on both sides. Its not just the anode issue.

Its also that Hyundai didnt follow LG's recommended charge profile for the cells so they are splitting the costs 30/70 (Hyundai/LG).

http://www.koreaherald.com/view.php?ud=20210304001084

So, clearly LG are shouldering the lions share. Expensive on both sides either way! If anything Hyundai is worse off as it's reputation is seriously affected now.

slave1 · 05-03-2021 7:43pm

Hyundai, you peaked with your first effort, the wonderful Ioniq28

innrain · 29-03-2021 10:12pm

US recall document

19-04-2021 12:59pm

Deleted User wrote: »

Father's Kona has twice had to be towed off driveway after a full charge. Last time they said that they'd fixed it - no problems since, but should I be advising him to keep an eye on the charging and not leave it go above 90%? Seems to be conflicting suggestions in many places.

Should have updated on this.

After having the car with Hyundai Ireland for 2 weeks last time, they said they replaced any problematic battery modules and fault should not reappear.

Famous last words!

Car charged overnight 2 weeks ago and when Dad got to it in the morning same error was back. Unable to start the car - big dead lump on the driveway.
Car back with Hyundai Ireland since then, apparently having full battery replacement, we're yet to hear of a date when we should see it back.

Loaner car same spec so Dad not too concerned, however does mean that anyone who thinks that their car has been sorted may need to think again.

19-04-2021 1:15pm

Measuring voltage on the starter battery would be interesting. A multimeter only costs 5 quid. It tells you nothing about amperage but just knowing if the battery is at 12.6V then that is something.

innrain · 19-04-2021 1:38pm

Deleted User wrote: »

Measuring voltage on the starter battery would be interesting. A multimeter only costs 5 quid. It tells you nothing about amperage but just knowing if the battery is at 12.6V then that is something.

OP refers to a different fault in the high voltage batteries that some Konas would developed after the last software upgrades. The software tightened to tolerances at high state of charge and trows errors much faster. This was designed to eliminate potential causes for fires and detect those batteries with fault. Unfortunately didn't work and as it stands the recommendation from Hyundai (in US) is to limit the state of charge until the full battery is replaced. In the recall document posted few weeks ago:

Hyundai plans to notify owners to bring their vehicles to the nearest
Hyundai dealership for replacement of the BSA. As an interim step, Hyundai plans to notify owners to bring their vehicles to the nearest dealership to have the battery’s state of charge limit lowered to mitigate risk. Owners will also be provided with instructions to manually lower the battery’s state of charge limit via the infotainment system. If customers are unable to successfully make these changes, or do not feel comfortable making these changes, they will be advised to not park their car inside, in their garage or carport until after they have visited their dealer.

Juan Jolly Lodge did your father charge the car to 100%?

19-04-2021 3:20pm

Was told not to (by me, but not Hyundai) - but yes car was charged to 100% when it became immobilised.

Old diesel · 19-04-2021 5:13pm

Ive seen 3 people on IEVOA facebook that have had or need a battery replacement.

Plus there was a Kona on done deal with a replacement battery on it.

I suspect whats happening is that the initial software "fix" for the fires is picking up issues (which was the whole idea of it in first place).

Hopefully replacement batteries will do better

Edit - missed Innrains post

innrain · 19-05-2021 11:06am

UK Recall
https://www.check-vehicle-recalls.service.gov.uk/recall-type/vehicle/make/HYUNDAI/model/KONA%20EV/year/2019/recalls

Less details than the US one but the same recommendation to limit the SoC followed by complete replacement.

19-05-2021 12:55pm

Deleted User wrote: »

Should have updated on this.

After having the car with Hyundai Ireland for 2 weeks last time, they said they replaced any problematic battery modules and fault should not reappear.

Famous last words!

Car charged overnight 2 weeks ago and when Dad got to it in the morning same error was back. Unable to start the car - big dead lump on the driveway.
Car back with Hyundai Ireland since then, apparently having full battery replacement, we're yet to hear of a date when we should see it back.

Loaner car same spec so Dad not too concerned, however does mean that anyone who thinks that their car has been sorted may need to think again.

One month update - still driving loaner Kona. Car with Hyundai Ireland. Updates and info have been s....p....a.....r.....s......e

slave1 · 19-05-2021 3:27pm

Kona battery replacement already begun in Ireland, takes about three weeks

19-05-2021 3:37pm

slave1 wrote: »

Kona battery replacement already begun in Ireland, takes about three weeks

Not my fathers' experience!

innrain · 19-05-2021 4:44pm

slave1 wrote: »

Kona battery replacement already begun in Ireland, takes about three weeks

Began for those that failed or is a open wide campaign? I can't see anything publicly available.

slave1 · 19-05-2021 6:18pm

Deleted User wrote: »

Not my fathers' experience!

Unlucky so, our Kona was three weeks getting replacement

slave1 · 19-05-2021 6:19pm

innrain wrote: »

Began for those that failed or is a open wide campaign? I can't see anything publicly available.

No idea, contact was made, car taken away, car returned, from what they said it was the first replacement in Ireland

10-10-20 · 20-05-2021 10:17am

slave1 wrote: »

Unlucky so, our Kona was three weeks getting replacement

Three weeks after a fault specifically, or three weeks after being proactively called in?
And what was the loaner car? Kona Petrol?

slave1 · 20-05-2021 11:20am

10-10-20 wrote: »

Three weeks after a fault specifically, or three weeks after being proactively called in?
And what was the loaner car? Kona Petrol?

Proactively, didn't need loaner as had just bought it so had "spare" car

10-10-20 · 20-05-2021 12:12pm

Pardon my line of questioning here, but... you were proactively called for a battery replacement and that replacement took three weeks to what, import, prepare and install the battery...? Was there an indication of the reason for the duration?

I'm simply aghast at a duration of three weeks for a modular replacement. This thing, while heavy, isn't like it's not on the workshop manual! Were they so unprepared that they had to wait for a new battery to ship from Korea after checking in your car?? Is three weeks the expected duration for all swaps???

Old diesel · 20-05-2021 1:08pm

10-10-20 wrote: »

Pardon my line of questioning here, but... you were proactively called for a battery replacement and that replacement took three weeks to what, import, prepare and install the battery...? Was there an indication of the reason for the duration?

I'm simply aghast at a duration of three weeks for a modular replacement. This thing, while heavy, isn't like it's not on the workshop manual! Were they so unprepared that they had to wait for a new battery to ship from Korea after checking in your car?? Is three weeks the expected duration for all swaps???

THIS.....

Leaf battery swops can be done a lot quicker - as in 1 day should do it

slave1 · 20-05-2021 2:34pm

Tesla swaps are 7minutes, the real time however is diagnosing the battery needs replacing and then waiting on parts, there is also a lot of testing afterwards

Old diesel · 20-05-2021 2:43pm

slave1 wrote: »

Tesla swaps are 7minutes, the real time however is diagnosing the battery needs replacing and then waiting on parts, there is also a lot of testing afterwards

Very true....

However i thought the poster was saying their car was called in by Hyundai as per recall.

So the swop is already pre planned and youd think the battery would be there waiting for the car.

I thought Hyundai were just going straight for replacement for the latest recall

zg3409 · 22-05-2021 4:38pm

Old diesel wrote: »

Very true....

However i thought the poster was saying their car was called in by Hyundai as per recall.

So the swop is already pre planned and youd think the battery would be there waiting for the car.

I thought Hyundai were just going straight for replacement for the latest recall

I suspect if this was first one they may have needed UK expert on site and to train up mechanics from other dealerships on how to do this. They are possibly stripping down entire battery into individual cells and replacing every cell and keeping the same wiring and enclosure. As mentioned by someone they then need to charge and discharge the cells and balance and test them. It might be possible to this in a day, but not at your first attempt. These batteries also have coolant piping which may need to be drained and disconnected from every cell. Ideally they would have a pack preprepared from another car, and swap out in a day and have this pack pretested in a central expert site. I know I would prefer they return the car full and fully tested through a few charge discharge cycles so the car re-learns the best estimated range.

innrain · 22-05-2021 5:36pm

I see on FB someone saying their car didn't start and he was notified that a battery replacement will happen. 3 weeks estimated and Kona 211 provided for the period. Maybe they do it in the UK? SK?

zg3409 · 11-06-2021 6:40pm

This was posted today to Facebook. From Hyundai Ireland. Posted to an owner.

Smee_Again · 11-06-2021 6:42pm

I got the same along with instructions on how to limit the battery to 90%.

BigAl81 · 12-06-2021 12:25am

Was that for an Ioniq or Kona do you know?

Smee_Again · 12-06-2021 12:29am

BigAl81 wrote: »

Was that for an Ioniq or Kona do you know?

Kona.

Hyundai Kona/Ioniq38 battery replacement

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