2019 Hyundai Ioniq Plug-In Hybrid

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

Component that failed: The charging inlet locking actuator (Hyundai: "charging connector lock/unlock actuator") on my 2019 Hyundai IONIQ Plug-In Hybrid. It locks the connector to the inlet. The failed actuator is STILL INSTALLED and available for inspection at a dealership. Safety risk: Hyundai TSB #18-BE-018 requires technicians to disconnect the high-voltage safety plug, wait 5 minutes for capacitor discharge, and wear insulated gloves because the area contains "high voltage components." A locked actuator forces owners to pry at an energized connector—shock hazard. A partially engaged connection risks arcing and fire. Charging failure also depletes the traction battery, cutting power available for merging and evasive maneuvers. Incident: Without warning, the connector would not release. It took ~30 minutes to free the charger. I nearly had to drive with the charger connected, feeding the cord through my driver's window. No warning lamps appeared before or during the failure. Confirmed by dealer: Yes. Diagnosed by [XXX] Hyundai on XXX, invoice XXX. Inspections: Dealer only. No police report, insurance claim, or known HMA engineering inspection. Manufacturer knowledge: Hyundai issued TSB #18-BE-018 in Nov 2018, while 2019 models were being sold, acknowledging IONIQ PHEVs "may experience a charging connector lock/unlock actuator malfunction," with warranty coding (Op Code 91999R00; Nature Cause I14 ZZ3). Hyundai said my VIN fell outside the recall population under undisclosed criteria, and covers the part only 5yr/60k, not the 10yr/100k Hybrid System Warranty. Requested action: (1) Evaluate whether this is a safety defect under 49 U.S.C. Ch. 301. (2) Obtain Hyundai's claim volume for Op Code 91999R00/I14 ZZ3 by model year, plant, build range, plus injury/fire reports. (3) Confirm whether a recall covers this component and publish its scope. (4) Assess whether Hyundai's exclusion of my VIN was adequately supported. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11772541

Incident

Sep 8, 2026

Supplemental to my complaint filed April 18, 2026 regarding Dick's Hillsboro Hyundai (dealer code OR035). The dealership's Service Manager (Robin Farr) provided me with an HMA training report from Hyundai's internal system. Every staff member is listed at "Certified": the baseline tier. No one is above this level. No EV/HEV-specific certification is indicated for any individual. Despite this, the dealership confirmed by phone they could service a 2019 Ioniq PHEV, then performed ICCU/DC-DC converter diagnostics (a hybrid electrical system procedure) and a 12V battery installation in the boot area adjacent to high-voltage components. The vehicle was returned with the hold-down bracket unsecured and retaining bolts missing which was only discovered when my car was assessed by a second Hyundai dealership after I had driven a significant distance. Hyundai's own shop manuals state: "Never allow technician to work on high voltage systems who are not wearing personal protective equipment." Hyundai TSBs for hybrid repairs require insulating gloves rated at 1000V AC/1500V DC. HMA's CPO form (HMACPO0601) requires an "EV/HEV Inspection certified technician" for hybrid-specific work. The ASE xEV Safety Standards state employers "SHALL verify" technician ability to work on HV systems. The dealership's website also claims its service department includes "Master technicians." The HMA training report shows no staff at that level. The Ioniq PHEV boot area contains HV wiring (DC 240V-360V). A loose metal bracket contacting terminals or HV wiring could cause a short circuit, arc, or fire — the type of hazard EV/HEV training exists to prevent.

NHTSA ID

11733084

Incident

Apr 3, 2026

Following a 12V auxiliary battery replacement at Dick's Hillsboro Hyundai [XXX] , April 3, 2026), the battery hold-down bracket was left completely unsecured. The retaining bolts were absent, (later found loose in the cargo tray area). The battery terminal cover was also improperly secured. I returned to the dealership within twenty minutes of collecting my vehicle and described the condition directly to Service Manager Robin Farr, who assured me it would be corrected. It was not. On April 6, 2026, Withnell Hyundai in Salem, OR (RO# XXX/X) identified the bracket as completely unsecured with me present, documenting: "found the 12V bracket loose on arrival" and "found that battery hold down was not secured with customer present...bolts were located in cargo tray area." I had driven approximately 50 miles with this condition unknown to me. On a 2019 Hyundai Ioniq PHEV, the 12V battery is located in the boot adjacent to high-voltage traction battery components and wiring. A loose metal bracket free to move during driving presents a genuine risk of electrical arc and fire in an enclosed space: potentially while the vehicle is in motion. Dick's acknowledged the failure in writing and refunded the charges associated with this work. The condition has been corrected by Withnell Hyundai. I am filing this report to create a federal record of a safety-critical installation failure at a certified Hyundai dealership. I contacted Hyundai Motor America (Case #XXX) regarding this matter. Their representative was unable to describe any oversight mechanism ensuring safe repairs at certified Hyundai dealerships. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11732091

Incident

Apr 3, 2026

While driving the transmission started driving rough and the car was stuck in ev mode. Wouldnt even go back to hybrid mode. I kept driving until all my battery range was exhausted and lost acceleration and had to pull over the side of the highway. It was late at night so there was no one around or behind me, otherwise I would have been hit. Once stopped the car would not move at all so I called a tow to get me off the highway. I was away from home and had to tow it 120 miles back to the local dealer. The engine clutch actuator failed and ruined my transmission and left me stranded in the middle of the night!

NHTSA ID

11677139

Incident

Apr 25, 2025

Many times, when I back out of my driveway into the intersection in front of my house the vehicle hesitates for several seconds when shifted from Reverse to Drive. I am in a situation where I cannot accelerate if needed out of the intersection. This is a safety issue in my opinion. The dealer was not able to replicate the problem, even though it happens frequently and has not provided a solution. One time, on a long road trip, while climbing a grade the vehicle could not achieve normal highway speeds (could only get to 20-30 mph). Big rigs were right behind the vehicle and were not happy having to slow down. Again creating a big safety hazard.

NHTSA ID

11578030

Incident

May 8, 2023

The rear driver's side seat belt completely detached from the shoulder attachment point.

NHTSA ID

11558101

Incident

Dec 1, 2023

Seat belts are stuck and most times does not get intact or reset after you get out of car seat. It has been happening over a month.

NHTSA ID

11508079

Incident

Feb 19, 2023

In the middle lane of a multiple lane highway, it suddenly gave a very confusing warning on the dashboard. It lost power and slowed down quickly to below 40 mph. It didn't help to press down the gas pedal. I was forced to switch from the middle lane to the passing lane in order to reach the shoulder. The car was side swept by another car in the passing lane because it was at low speed. Once it reached on the shoulder it stopped completely. If it gave a clear warning, for example, "pull out immediately!", and flashed the emergency light automatically, it might save a few seconds, and gave a warning to cars behind. It's a PHEV, and I believe that it used up the battery for driving but failed to automatically start the gas engine.

NHTSA ID

11474067

Incident

Jun 14, 2022

Some vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin outlines the combustion chamber cleaning procedure for vehicles diagnosed with this condition. All internal combustion engines consume some engine oil during normal operation, depending on driving conditions and mileage, and this procedure should only be performed when deemed necessary based on inspection and diagnosis of the vehicle as outlined in TSB 26-EM-015H, Engine Oil Consumption – Inspection & Repair Guidelines, or the latest revision.

Certain vehicles equipped with internal combustion engines may exhibit higher-than-expected engine oil consumption. This bulletin provides the inspection and repair procedures for vehicles exhibiting this condition. All internal combustion engines consume engine oil as part of normal engine operation. Oil consumption rates may vary based on mileage, operating conditions, driving habits, and maintenance history. Hyundai recommends following the prescribed maintenance schedule and periodically checking the engine oil level using the dipstick to maintain proper engine oil level.

The National Highway Traffic Safety Administration (NHTSA) has identified the presence of substandard and dangerous driver’s-side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN). These inflators were not supplied, approved, or authorized by the vehicle manufacturers and have primarily been found in vehicles that previously experienced a crash and underwent airbag replacement using non-genuine parts. These dangerous inflators have ruptured during deployment, posing a serious risk of injury or death due to metal fragments entering the vehicle cabin. To date, Hyundai is aware of three people who have died while driving a Hyundai vehicle with one of these substandard replacement airbag inflators that deployed in what likely would have been a survivable crash. NHTSA has issued a public advisory urging vehicle owners and service professionals to have vehicles inspected if there is reason to believe that a non-genuine replacement airbag may have been installed. Vehicles with salvage or rebuilt titles, prior airbag deployments, or unknown repair histories may present a higher risk. NHTSA strongly cautions against self-inspection by vehicle owners and recommends inspection by trained technicians.

The National Highway Traffic Safety Administration (NHTSA) has issued an urgent safety advisory regarding dangerous, counterfeit driver‑side airbag inflators manufactured by Jilin Province Detiannuo Automobile Safety System Co., Ltd. (DTN), that have been identified in U.S. vehicles following prior crashes, theft, or non‑certified airbag replacements. These inflators are not approved for use, may rupture during deployment, and have caused serious injuries and fatalities. Please see attached announcement, provided by NHTSA, for more details.

This bulletin provides information regarding condensation related to the accumulated moisture in the headlamp, rear combination lamp, daytime running lamp (DRL), or fog lamp. This TSB illustrates the various causes of condensation inside the lamp assembly. Lamp assembly replacement is NOT necessary in most cases. This condition can be eliminated by turning on the lamps with the engine running for several minutes or during normal driving operation.

Some vehicles may exhibit a loss of connectivity or interruptions in the middle of using Bluelink Service functions. This may be due to an irregular disconnection on Verizon’s communication network. Follow the procedure in this TSB to reestablish the connection via the AVN pinhole reset method.