NHTSA Complaint #11713986 — 2022 HYUNDAI IONIQ 5

The component that malfunctioned is the Integrated Charge Control Unit (ICCU) and related high-voltage charging system in my 2022 Hyundai Ioniq 5. The ICCU controls AC (Level 2) charging, DC fast charging functions, and power delivery. The ICCU assembly and charging components were serviced and replaced by an authorized Hyundai dealer and are available for inspection through service records. This defect created a safety risk because the vehicle experienced complete charging failure and reduced-power operation. Loss of charging capability can leave drivers stranded, and reduced-power “turtle mode” conditions can limit acceleration and vehicle performance, creating hazards in traffic. The charge port has also not locked during charging, creating a potential risk of electrical arcing during DC fast charging. The failure was reproduced and confirmed by an authorized Hyundai dealer. In approximately January 2025 the vehicle would not charge and remained at the dealership for an extended period (about January through June 2025). After diagnosis and consultation with Hyundai technical support, the dealer replaced the ICCU assembly and high-voltage fuse. The vehicle and charging system have been inspected multiple times by Hyundai service centers. Hyundai issued recall campaigns in 2023 and 2024 involving ICCU software updates and fuse-related work, but these did not prevent the later failure requiring full ICCU replacement. Prior symptoms included abnormal charging behavior and eventual total loss of AC charging capability during the 2025 failure, making home charging impossible. After the ICCU replacement, the vehicle exhibited unusually loud cooling fan operation during Level 2 charging, documented by the dealer. There were also charging-port safety concerns. After one service visit, an important DC pin cover/cap was not properly installed until corrected on a return visit, leaving charging components exposed.