March 14, 2024 NHTSA CAMPAIGN NUMBER: 24V200000
Loss of Drive Power from Damaged Charging Unit
A loss of drive power increases the risk of a crash.
NHTSA Campaign Number: 24V200000
Manufacturer Kia
America, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 48,232
Summary
Kia America, Inc. (Kia) is recalling certain 2022-2024 EV6 vehicles. The Integrated Charging Control Unit (ICCU) may become damaged and stop charging the 12-Volt battery, which can result in a loss of drive power.
Remedy
Dealers will inspect and replace the ICCU and its fuse, as necessary. In addition, dealers will update the ICCU software. All repairs will be performed free of charge. Owner notification letters are expected to be mailed April 29, 2024. Owners may contact Kia customer service at 1-800-333-4542. Kia’s number for this recall is SC302.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Kia has a Recall
2022-2024MY EV6
ICCU Assembly
Basis of Safety Defect Determination 573.6(c)(6)
May 10, 2023
Kia North America (Kia NA) Safety Office provides information relating to Integrated Charging Control Unit (ICCU) and associated limp home mode condition involving 2022-2023MY EV6 vehicles during meeting with National Highway Traffic Safety Administration’s (NHTSA) Office of Defect Investigation (ODI).
May 29, 2023
Kia NA Safety Office informs ODI of its plan to conduct a voluntary service campaign for certain 2022-2023MY EV6 vehicles regarding the ICCU.
May 30, 2023
Kia NA Safety Office decides to conduct a voluntary service campaign (SC271) to address an over current condition in the high voltage system that can result in multiple warnings and gradual reductions in power. Three (3) cases report loss of motive power with warnings; no cases report loss of motive power without warnings. No injuries, crashes, fatalities or fires.
July 3, 2023
ODI opens PE23-012 to investigate “consumer report experiencing a reduced or complete loss of motive power during vehicle operation increasing the risk of a crash” involving 2022MY EV6 vehicles.
July 11, 2023—July 13, 2023
Kia NA issues SC271 dealer and owner notifications.
August 18, 2023—October 23, 2023
Kia NA submits responses to PE23-012 information requests and concludes no unreasonable risk to motor vehicle safety exists due to 1) progressive and lengthy audible and visual warnings and messages, including instructing customer to stop the vehicle; 2) the ability to continue to drive vehicle with progressive reductions in power; and 3) low incident rate with no reported fires, accidents or injuries.
February 5, 2024—February 14, 2024
Kia Corporation (Kia HQ) informs Kia NA Safety Office of elevated claims following SC271 software upgrade in other global markets. Kia NA Safety Office preliminary data analysis identifies a total of 25 unique reports of loss of motive power after receiving software update under SC271 and shares results with Kia HQ.
February 19, 2024
Kia HQ provides Kia NA Safety Office with investigation results showing the ICCUs collected from global markets show signs of damage after thermal cycling and exposure to transient voltage peaks.
March 1, 2024
Kia NA Safety Office escalates issue to SEL.
March 7, 2024
Kia HQ informs Kia NA Safety Office of newly developed software which was incorporated into production on 2/27/2024.
Kia NA Safety Office updates data analysis and identifies a total of 34 unique reports of loss of motive power after receiving software update. [33 warranty claims; 2 techline cases and 2 customer complaints (dates of receipt 9/20/2023—2/29/2024)]. No injuries, crashes, fatalities or fires.
March 8, 2024
Kia NA decides to recall all 2022-2023MY EV6 vehicles and certain 2024MY EV6 vehicles. No injuries, crashes, fatalities or fires.
3 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| KIA | EV6 | 2022-2024 |
3 Associated Documents
Recall Acknowledgement
RCAK-24V200-6943.pdf 645.425KB
2022-2024MY EV6 ICCU Assembly Chronology
RMISC-24V200-5381.pdf 86.273KB
Defect Notice 573 Report
RCLRPT-24V200-2390.PDF 214.117KB
Kia Reprogramming
Kia J2534 Diagnostics & Reprogramming
https://kiatechinfo.snapon.com/J2534DiagnosticsAndProgramming.aspx
What is J2534?
A single set of programming hardware consists of personal computer(PC), standard interface to a device driver and an interface hardware that connects between PC and a programmable ECU of vehicle.
The main purpose of this regulation is to program ECUs for all vehicles using a single set in the field.
| Device | Manufacturers | API | DLL | Firmware |
|---|---|---|---|---|
| CarDAQ Plus | Drew Technologies Inc. | 4.04 | 1.9.28 | 1.9.28 |
| ES6510 | Vetronix Corporation | 4.04 | 12.00 | 12.00 |
| Sun PassThru Pro | Snap-on Diagnostics | 4.04 | 02.07u | 02.07u |
| PassThru+ XS | I+ME Actia GmbH | 4.04 | 02.07u | 02.07u |
| OTTOTEST-VCI | OTTO | 4.04 | 1.04 | 1.34 |
| iFlash | Blue Streak | 4.04 | 1.04 | 1.34 |
| PASS THRU PRO II | Snap-on Diagnostics | 4.04 | 1.9.24 | 1.9.24 |
| AEZ Flasher | AE Tools | 4.04 | 1.9.28 | 1.9.28 |
| VSI-2534 | Dearborn Tech | 4.04 | 2.05.26 | 2.05.26 |
| Flasher Pro | Bosch | 4.04 | 1.9.28 | 1.9.28 |
| Flash2 | Cardone | 4.04 | 2.06.28.2 | 2.06.28.2 |
| PX3 | Dearborn Tech | 4.04 | 1.00.09 | 1.00.09 |
| CARDAQ-M | Drew Technologies Inc. | 4.04 | 1.0.106 | 1.0.106 |
| Universal Reprogrammer II | EASE Diagnostics | 4.04 | 1.9.28 | 1.9.28 |
| G-Scan2 | GIT | 4.04 | 3.1 | 9.03 |
* API, DLL and Firmware version may be controlled by the device manufacturer. Contact the manufacturer if you are unable to find the version listed above All devices were tested/verified on all Hyundai engine management systems.
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SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-200
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Kia America, Inc. MAR 14, 2024 NHTSA Recall No. : 24V-200 Manufacturer Recall No. : SC302 Manufacturer Information :
Manufacturer Name : Kia America, Inc.
Address : 111 Peters Canyon Road
Irvine CA 92606 Company phone : 800-333-4542
Population :
Number of potentially involved : 48,232 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2022-2024 Kia EV6 Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All 2022-2023 model year and certain 2024 model year EV6 vehicles manufactured from November 17, 2021 through February 7, 2024 (48,232 units). The recall population was determined by a review of vehicle and supplier production records. The vehicles subject to this recall were not produced in VIN order.
Customers seeking information about their specific vehicle will be referred to Kia’s Customer Care Center or their Kia dealer. Production Dates : NOV 17, 2021 – FEB 07, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The Integrated Charging Control Unit (ICCU) may become damaged over time from transient high voltage and thermal cycling. A damaged ICCU may not be able to charge the 12-volt battery which can discharge gradually while driving with progressive reductions of motive power. If the driver ignores the warnings associated with the discharging battery condition and continues to operate the vehicle in a reduced power mode, the vehicle may eventually experience a complete loss of motive power.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A loss of motive power increases the risk of a crash. Description of the Cause : Thermal loading and transient high voltage can damage the ICCU. Part 573 Safety Recall Report 24V-200 Page 2 Identification of Any Warning
that can Occur : Audible warning chimes and one or more of the following: Illumination of “Check Electric Vehicle System” warning light, Master warning light, Charging system warning light, “Stop vehicle and check power supply” warning light, power down (turtle) warning light and /or reductions in motive power. Involved Components : Component Name 1 : ICCU ASSY Component Description : ICCU Assembly
Component Part Number : 36400-1XFA0 / 36400-1XFA0QQK Supplier Identification : Component Manufacturer
Name : Hyundai Mobis
Address : 203 Teheran-ro, Gangnam-gu Seoul Foreign States 06141
Country : Korea, Republic of Chronology :
See attached document titled “2022-2024MY EV6 ICCU Assembly Chronology”. Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicles to a Kia dealer. Kia dealers will inspect the ICCU and if necessary, replace the ICCU and ICCU fuse. Dealers will also install updated software to address the recall condition. Kia will reimburse owners for repair expenses already incurred pursuant to Kia’s General Reimbursement Plan filed May 10, 2022. How Remedy Component Differs from Recalled Component : The improved ICCU software decreases thermal loading and lowers peak voltage during operation to mitigate damage to the ICCU. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-200
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
2024MY EV6 vehicles manufactured after 2/27/2024 were produced with improved ICCU software. 2024MY EV6 vehicles produced from 2/8/24 to 2/27/2024 are being repaired at the port prior to distribution to dealers and thus are not included within the scope of this recall. Recall Schedule :
Description of Recall Schedule : The planned dealer notification start and end date is April 25, 2024. The
planned owner notification start and end date is April 29, 2024.
Planned Dealer Notification Date : APR 25, 2024 – APR 25, 2024
Planned Owner Notification Date : APR 29, 2024 – APR 29, 2024
* NR – Not Reported
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SEOCONTENT-END
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