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Hyundai IONIQ Hybrid/PHEV: main relay, contacts and local heat damage

22V-459, previous-repair checks and limits across IONIQ powertrains.

Specified MY2017–2018 IONIQ HEV/PHEV only; not Electric or IONIQ 5/6 · USA. Model years covered: 2017–2018.

The inspection framework was prepared by the editorial team. Repair procedures and parts applicability depend on documentation for the specific vehicle version.

Identify the powertrain first

IIHS expressly separates Hybrid/PHEV ratings from IONIQ Electric. In 22V-459 Hyundai lists certain MY2017–2018 HEV/PHV previously included in Recall 178. IONIQ does not transfer this mechanism to Electric or IONIQ 5/6.

Insurance Institute for Highway Safety: IIHS: 2018 Hyundai Ioniq HybridHyundai Motor America / NHTSA repository: Part 573 Safety Recall Report 22V-459 / Hyundai 232

An IONIQ2018 entry alone leaves powertrain unresolved. Hybrid parts, relay schemes and another configuration’s procedure cannot be assumed applicable.

Contact, resistance and heat

The June 28, 2022 report describes a problematic main-relay contact connection in the Power Relay Assembly. Extended operation could increase resistance and heat, risking a thermal event. HEV warnings and no-start are possible signs. This is an assembly mechanism, not proof of damage to the entire traction battery.

Hyundai Motor America / NHTSA repository: Part 573 Safety Recall Report 22V-459 / Hyundai 232

Name housing, contact, connector or nearby wiring precisely. One darkened component does not establish every neighbour’s condition. Without opening/testing under the appropriate procedure, internal state remains unknown.

An earlier recall entry does not close the check

Hyundai states some vehicles may not have received proper components in the earlier campaign. The 22V-459 remedy checks that correction and replaces the main relay or PRA if needed. Recall completed alone cannot establish the correct installed components.

Hyundai Motor America / NHTSA repository: Part 573 Safety Recall Report 22V-459 / Hyundai 232

Current coverage, actual component identity and inspection are required. An invoice confirms recorded work, not its physical condition or an automatic cause of later damage.

Impact, moisture and overheating: separate observations

External damage or cabin moisture must be documented separately from the relay scenario. Causation requires contact location, baseline images, timing and tests. Two events in the history do not determine which caused a defect.

No HV shutdown/disassembly is proposed. Keep electrical assemblies distinct and identify evidence for the actual finding. Unsupported battery assumptions do not belong in the established-defect list.

Crash testing has another scope

IIHS publishes CEN1723 for a MY2017 IONIQ Hybrid Limited with ratings MY2017–2022. This does not expand 22V-459 to all those years. The controlled protocol does not test every relay contact after third-party repair.

Insurance Institute for Highway Safety: IIHS: 2018 Hyundai Ioniq Hybrid

Applicability to the individual vehicle

  • Unknown held IONIQ2018 powertrain remains unresolved; no private-case fitment verified.
  • Recall scope is previously recalled MY2017–2018 HEV/PHV, not the MY2017–2022 test family or Electric.
  • Relay heat does not prove battery damage or collision causation.

Primary sources

Sources checked on . Model or recall information does not establish the condition of an individual VIN.

Hyundai Motor America / NHTSA repository: Part 573 Safety Recall Report 22V-459 / Hyundai 232

Applicability and source location

Certain MY2017–2018 HEV/PHV previously in Recall178, with separate build dates. Not Electric, IONIQ5/6 or all MY2017–2022 hybrids.

Pages 1–2: prior remedy, relay-pin fit, resistance/heat and warnings; page 3: inspect prior work, replace as needed.

Document date: 2022-06-28. Checked: .

Insurance Institute for Highway Safety: IIHS: 2018 Hyundai Ioniq Hybrid

Applicability and source location

Hybrid test CEN1723, rating MY2017–2022 Hybrid/PHEV, expressly not Electric.

2017 Hybrid Limited CEN1723; powertrain applicability distinction.

Document date: not specified in the source. Checked: .

Model overview · Ukrainian: Hyundai IONIQ