2022 Hyundai IONIQ 5 ICCU Failure

Class Action Investigation

Updated on Author: Sergei Lemberg

Updated on Author: Sergei Lemberg

Lemberg Law is investigating complaints that the award-winning 2022 Hyundai IONIQ 5 has catastrophic Integrated Charging Control Unit (ICCU) failures. The first vehicle built on Hyundai’s new Electric-Global Modular Platform (E-GMP), it features the world’s first integrated power electric system that incorporates a newly developed ICCU. The automaker claims that the new EV platform “gives us the opportunity to re-create a new mobility experience.” But many owners are finding that their new IONIQ 5 EVs develop a power supply error. Even if the battery is fully charged, vehicles shut down, and often leave them stranded with no mobility at all.   

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Is There a Problem with the ICCU?

There is a major problem with the 2022 Hyundai IONIQ 5 that it shares with the 2022 Kia EV6 that is built on the same E-GMP, its first dedicated BEV (Battery Electric Vehicle) platform. Even though Kia operates independently, it is owned by Hyundai Motor Group, and the Kia EV6 and Hyundai IONIQ 5 have the same Hyundai Integrated Charging Control Unit (ICCU). So, it stands to reason that because there is a problem with the ICCU, both vehicles are affected. We know this to be true, because owners of both vehicles are reporting bad experiences with the ICCU. You can read complaints about the 2022 Kia EV6 ICCU failure here.

While many dealers appear to have no idea what the problem is, some have identified that the ICCU is the problem with the IONIQ 5. But the required ICCU replacement and parts aren’t readily available and have to be ordered from South Korea.

The result is that complaints are rampant. Those filed with the National Highway Traffic Safety Administration (NHTSA) are all relatively recent, dating from March 1, 2023. Comments about the issue on the IONIQ Forum and on Reddit started at a similar time.

What ICCU Problems are Owners Experiencing?

Complaints to the NHTSA and various discussions on the IONIQ Forum and Reddit describe the problems that 2022 Hyundai IONIQ 5 owners are experiencing. They are very similar in many ways.

Complaints to the NHTSA Say Check EV System

Commonly, NHTSA complaints mention warnings or error messages that relate to the batteries and/or electric system. They say that almost immediately, the speed of the vehicle drops to 24-25 mph. Some complaints express serious concerns about safety issues.

If You Hear Pop, Check Your Electric System

The very first NHTSA complaint on March 1, 2023, states that there was a “pop” sound and then a warning to “Check EV system.” A few minutes later the car beeped loudly and the message, “Stop vehicle and check power supply.” A diagnostic scanner reported a P1A9096 code, which “makes the vehicle inoperable with little warning.” Although the complaint doesn’t state this, according to the IONIQ manual, if this message pops up you need to stop your car and have it towed to a dealership. A later complaint that describes the same pop sound and message states, “This is likely the ICCU+Fuse failure that seems to be happening to many owners of the IONIQ 5.”

Other complaints tell how the IONIQ 5 loses power after the various error messages show up. For example, after one owner had been driving for just a few minutes, the warning “Check Electric Vehicle System” displayed. Then the vehicle slowed down and they had “to limp back home, where it is now parked. Hyundai has not had availability to diagnose the issue.”

Another owner also heard a loud sound alert before seeing an error message, “Stop vehicle and check power supply” on the dashboard. The 12V battery was still plugged in, but the error message wouldn’t go away. “I limped home, called a tow truck to take it to the nearest Hyundai that services electric vehicles, and they told me they’d have to replace the ICCU, which is backordered.”

Concerns of Safety Issues and Delays

Several owners have been stranded. After getting the “Stop vehicle and check power supply” message and “limping” for a short distance, an IONIQ 5 owner states he was left stranded by Hyundai roadside assist for 5 hours. Once he had the car towed to the dealership, it was diagnosed with an “ICCU/ICCU fuse issue. To date I am being told that the parts are on backorder for 2-3 weeks.”

Another complaint states that the speed dropping to no more than 24 mph nearly caused a collision. “After pulling over, I was able to limp into a safe area and call a tow truck. The service shop informed me that my Integrated Charge Control Unit and fuse needed to be replaced. I am still waiting for the part to come in (estimated delivery of two months).” The major concern here is that “Hyundai is quiet on how widespread the issue is, but given that there is a safety concern when one’s auto suddenly slows down while on a highway.”

What Owners Say on Forums and Reddit

On both platforms, owners of IONIQ 5 are sharing their experiences. These are just a few of the comments:

  • “My integrated charge control unit had a catastrophic failure yesterday afternoon coming back from NY suburbs in rush hour. This a week after the car was returned to me after a $15,000 collision repair (state trooper backed into me on shoulder). Estimated repair duration – two weeks. I’m covered with a rental car and the part is part of the warranty.”
  • “My ICCU died at 18k miles after 11 months. I also purchased in Feb 2022. I also charged mostly at EA and occasionally L2 in my garage. It isn’t a 2 week repair. Mine is in the shop (for) 7.5 weeks and the part hasn’t arrived. Doing a buyback.”
  • “My ICCU just kicked the bucket in NY too. Left my fiance stranded on the side of the road and me stranded at the airport. Purchased Feb 2022 with just under 14k miles on it. Dealership ordered the part. I’m not sure how long I’ll be without the car though. I anticipate that we’ll see a recall on this part sooner or later.”
  • “Welcome to the club of ICCU problems. Hyundai has to step up and admit there is a problem and at least keep a sufficient stock of replacement parts. This is not the same as a problem where the car can be driven while waiting for a fix, the car cannot be used with the fuse or ICCU defective.”
  • “I’m at 58 days with the car at the dealership, waiting for a new rear motor/gear assembly. Had to rent a car for a couple weeks to start, before the dealership put me in a loaner. Part was estimated to ship this past week, but no luck.”

Are 12V Battery and ICCU Issues Linked?

While it stands to reason that they probably are, there is no definitive guidance on this issue. There is also some confusion relating to a recall issued in South Korea for 2022 IONIQ 5 vehicles.

For example, this comment on IONIQ Forum illustrates the gray area regarding battery vs ICCU. “I took my 2022 AWD IONIQ 5 in for (the) T9Q service campaign that calls for a software update to enable (the) battery conditioning function. The first dealer tried and gave up saying there was an error during the update. I took the vehicle to another dealer in the Baltimore area on March 1 (2023). That dealer also reported an error but said they’d seek expert help and find out what was going on. A week later they reported that further diagnostics showed the ICCU (Integrated charge control unit) is faulty.“

Then, there is some confusion about the IONIQ 5 recall that has been identified by U.S. owners of the 2022 IONIQ 5. It seems to have started when the admin of a private Facebook IONIQ 5 group posted information about the recall.

The Recall Issued in South Korea

The Facebook admin states that according to the recall, the ICCU was improperly welded and allowed coolant leakage, leading to the 12-volt battery drain issue.

United Press International (IPU) reported in June 2021 that Hyundai had acknowledged the coolant leak. But there is no link to ICCU problems even though some owners think there is.

A March 2023 comment on reddit states: “Ioniq 5 recall (in S. Korea) and free repair related to battery discharge and coolant shortage warning lights due to defective integrated charging control unit (ICCU). Coolant leakage may occur due to insufficient optimization of welding conditions within ICCU. The ICCU is water (coolant) cooled. It looks like the ICCU cooling water flows through the condenser and the motor radiator. If this leakage happens within ICCU due to faulty welding, it can cause damage to ICCU components.”

NHTSA Investigation

The Office of Defects Investigation (ODI) has initiated an investigation into the 2022 Hyundai Ioniq 5 following 30 consumer complaints regarding a loss of motive power on June 8. 2023. The Preliminary Evaluation document states that owners have reported a loud pop noise, followed by a warning displayed on the dashboard, and subsequently experienced a range of power loss, from a reduction to a complete loss of motive power. ODI conducted interviews with owners, confirming the varying time intervals between the warning message and power loss. Hyundai has identified the Integrated Control Charging Unit (ICCU) as the source of the issue, with over-current potentially damaging transistors in the DC-to-DC converter, resulting in the inability to recharge the 12V battery. ODI is working to determine the extent and seriousness of the potential issue and conduct a comprehensive assessment of any safety-related concerns associated with it.

What Should You Do if Your Ioniq 5 has ICCU Problems?

Lots of people who are experiencing ICCU issues with their IONIQ 5 vehicles have been waiting for long periods of time for some form of resolution. This, in itself, may mean that they have vehicles that qualify in terms of lemon law.

If you are experiencing issues with your ICCU, you might qualify to join our class action investigation. You are welcome to contact Lemberg Law for advice. We will assess your problem free of charge. Every year automakers buy-back or trade in thousands of problem vehicles. Yours might be one of them.

All you need to do is call our Helpline or complete a contact form. The law says that Hyundai must pay the costs of lemon law cases… not you!

Sergei Lemberg

About the Author:

Sergei Lemberg is an attorney focusing on consumer law, class actions related to automotive issues, and personal injury litigation. With nearly two decades of experience, his areas of practice include Lemon Law (vehicle defects), Debt Collection Harassment, TCPA (illegal robocalls and texts), Fair Credit Reporting Act, Overtime claims, Personal Injury cases, and Class Actions. He has consistently been recognized as the nation's "most active consumer attorney." In 2020, Mr. Lemberg represented Noah Duguid before the United States Supreme Court in the landmark case Duguid v. Facebook. He is also the author of "Defanging Debt Collectors," a guide that empowers consumers to fight back against debt collectors and prevail, as well as "Lemon Law 101: The Laws That Lemon Dealers Don't Want You to Know."

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