2025 Hyundai Ioniq 5 HV Battery Charging Issue TSB

Symptoms

Owners of certain 2025 Hyundai Ioniq 5 (NEA EV) vehicles may experience a charging issue where the High Voltage Battery does not fully charge. This problem stems from a voltage difference detected between the battery cells. This specific 2025 Hyundai Ioniq 5 charging issue is typically identified by the presence of specific diagnostic trouble codes (DTCs) in the vehicle's Battery Management System (BMS).

Fault Codes / DTCs

This charging issue is associated with two specific Diagnostic Trouble Codes (DTCs) that will be stored in the Battery Management System (BMS):

Code	Description	Module
P1AA700	Hybrid/EV Battery Abnormal Performance: Cell Voltage Deviation	BMS
P1AD300	Hybrid/EV Battery Abnormal Performance: MISD	BMS

If either of these DTCs are found in an "Active" status, it indicates the need for further inspection and potential repair as outlined in TSB 25-EV-002H.

Diagnosis and Trigger Conditions

To diagnose the 2025 Hyundai Ioniq 5 charging issue, a technician must connect to the vehicle's Global Diagnostic System (GDS) and perform a Fault Code Search on the Battery Management System (BMS). If DTC P1AA700 and/or P1AD300 are active, the technician must submit the current BMS data and Freeze Frame data as a Techline case for review. This review is a mandatory step prior to placing an order for a replacement Battery System Assembly (BSA).

If neither of these specific DTCs are present, this Technical Service Bulletin 25-EV-002H does not apply, and further troubleshooting would be necessary for any other charging concerns.

Important Warnings for Owners and Technicians

Hyundai emphasizes that to avoid potential damage to IONIQ vehicles, all IONIQ repairs, including those related to this 2025 Hyundai Ioniq 5 charging issue, can only be performed at IONIQ certified dealers. This ensures that specialized technicians with the necessary training and equipment handle high voltage systems safely and correctly.

Technicians are also issued critical safety warnings: When working on the high voltage system, it is essential to read and comply with the "Safety Precautions, Cautions and Warnings" and to cut off the high voltage first per the “High Voltage Cut-off Procedure". Failure to comply with these safety instructions may result in serious accidents due to electric shock or leakage.

Repair Procedure Summary

The repair procedure outlined in TSB 25-EV-002H involves several key steps:

1. Diagnostic Check: Connect the GDS and perform a fault code search on the BMS system. Confirm if DTC P1AA700 and/or P1AD300 are active. If they are, submit BMS and Freeze Frame data to Techline for review.
2. Digital Documentation: This TSB requires repair validation photos. Technicians must use the STUI system to take a photo of the installed BSA's part label, including the last 6 digits of the VIN and the repair date written on a piece of paper. This photo must then be uploaded to STUI.
3. BSA Replacement: Replace the Battery System Assembly (BSA) by following the detailed instructions in the shop manual under "Battery Control System > High Voltage Battery System > Battery System Assembly (BSA) > Removal / Installation". It is crucial to ensure that one-time bolts are replaced and recommended torque specifications are applied to all fasteners to prevent future issues.

Required Parts

Depending on the specific Battery System Assembly (BSA) type (Long Range or Short Range), different part numbers are required for the replacement. Additionally, new bolts and coolant are necessary for the repair:

• BSA - Long Range: Part Number 37501-P1050
• BSA - Short Range: Part Number 37501-P1150
• BSA Bolt & Washer Assy: Part Number 37535-G1050 (8 required)
• BSA Bolt & Washer Assy: Part Number 37535-G1500 (18 required)
• Pink-Antifreeze / Coolant: Part Number 00232-19098 (2 gallons required)

Warranty Information

This repair for the 2025 Hyundai Ioniq 5 charging issue should be submitted as a “Campaign” type claim. The operation time for the Battery Inspection & Replacement is 2.9 M/H. The relevant warranty codes are:

• Operation Codes: 50DV03R0 (for BSA 37501-P1050) or 50DV03R1 (for BSA 37501-P1150)
• Causal Part: 37501-P1050 or 37501-P1150
• Nature Code: W11
• Cause Code: ZZ3

Warranty claims must include VIN, mileage, and repair validation photos. Incident parts are subject to callback, and claims may be debited if parts are not returned. Dealers will be reimbursed for 2 gallons of coolant under both operation codes.

NHTSA ID: 10255395