2022-2023 Hyundai Ioniq 5/6 EV Charging Port Cap TSB

Hyundai has issued Technical Service Bulletin (TSB) 23-EV-006H to address concerns regarding the EV charging port insulation caps on certain 2022-2023 Hyundai Ioniq 5 (NE1) and 2023 Hyundai Ioniq 6 (CE1) vehicles. This bulletin provides detailed service information for inspecting and, if necessary, replacing any missing or damaged insulation caps within the charging port. The integrity of these caps is crucial for ensuring correct charger connector orientation and a proper fit when connecting to the vehicle's charge port.

Important Notice for Owners

Owners should be aware of a critical restriction regarding this service campaign:

• "This service campaign can only be performed at certified IONIQ Hyundai dealers."

This means that only authorized Hyundai service centers are equipped and permitted to carry out the inspection and replacement procedures detailed in TSB 23-EV-006H.

Symptoms

The primary concern addressed by this TSB is the condition of the EV charging port insulation caps. Owners might not directly observe a symptom, but the absence or damage of these caps can lead to:

• Improper charger connector orientation.
• Poor fit of the charger to the vehicle's charge port.
• Potential for foreign material entry into the charging port.

These issues can compromise the charging process and the longevity of the charging system. The Hyundai Ioniq 5 charging port requires these caps for optimal function.

Repair Procedure Summary

The repair procedure outlined in TSB 23-EV-006H involves a multi-step process to ensure the proper function of the Hyundai Ioniq 5 charging port.

1. Open the Charging Port: The technician begins by opening the vehicle's charging port.
2. Charging Port Inspection: Both the AC charging terminals and the Quick (DC) charging terminal are thoroughly inspected. The inspection focuses on identifying any missing, damaged, or significantly deteriorated insulation caps. Technicians also check for any foreign matter present inside the port.
3. Foreign Material Removal: If foreign material is found, it is first blown out using shop air. For stubborn dirt, an electrical contact cleaner may be used, followed by another blast of shop air.
4. Cap Removal: Any damaged or deteriorated insulation caps are carefully removed using needle-nose pliers.
5. Cap Installation: A new insulation cap is temporarily mounted onto the terminal by hand. To fully secure the cap, a rod or a similar flat-tipped object (like the back of a screwdriver) is used to press it firmly into place.

Required Parts

To perform the necessary repairs, specific insulation caps are required:

• 91691-GI010: Insulation Cap - Inlet Terminal 5P Charge
• 91691-GI020: Insulation Cap - Inlet Terminal 5P GND
• 91691-GI030: Insulation Cap - Inlet Terminal 5P DC

Warranty Information

This service is covered under normal warranty conditions. The operation code for this service is 91690R00, with the operation name