2022 Hyundai Ioniq 5 Active Air Flap Actuator TSB

Symptoms

Owners of affected 2022 Hyundai Ioniq 5 vehicles may notice "AAF warning signs" while driving. These signs indicate that the Active Air Flap (AAF) may not be opening or closing correctly.

Fault Codes / DTCs

This issue is associated with a specific diagnostic trouble code (DTC):

Code	Description
U028400	Lost Communication with Active Air Flap Actuator

Diagnosis / Trigger Conditions

The primary trigger for this issue is an unstable power supply to the Active Air Flap (AAF) actuator. When the power supply is inconsistent, the AAF actuator may fail to operate as intended. This malfunction leads to the display of "AAF warning signs" and the storage of DTC U028400 in the vehicle's system.

Important Warnings

Owners and technicians should be aware of the following important information regarding this service campaign:

• This service campaign for IONIQ 5 (NE1) can only be performed by IONIQ certified Hyundai dealerships.
• Do NOT damage the front bumper covers and panels during any repair procedure.
• Do NOT damage the front bumper side hook.
• To prevent damaging trim and other parts, use a plastic tool or screwdriver wrapped with tape.
• Gloves are highly recommended to prevent injury to hands.
• If any clips are damaged during removal, replace them during reassembly.
• For dealerships, claims are subject to debit if the affected part is not returned as per the Warranty Technical Center (WTC) parts return process.

Repair Procedure Summary

Hyundai Technical Service Bulletin 23-01-075H outlines a detailed procedure for replacing the Active Air Flap (AAF) actuator. The repair begins with disconnecting the negative battery terminal and removing the front trunk assembly. Technicians then partially remove the fender garnish and the front bumper assembly to gain access.

Key steps include disconnecting the front bumper main connector and the AAF control unit connector. The faulty AAF actuator is then removed by loosening its mounting screws. A new AAF actuator, specific to either the left-hand (LH) or right-hand (RH) side, is installed. Proper alignment of a star-shaped protrusion into the matching hole in the AAF actuator is crucial during installation.

Finally, all components are reinstalled in the reverse order of disassembly, and the negative battery terminal is reconnected. The AAF system's normal operation is verified after the ignition is turned ON. The procedure concludes with checking for and clearing any stored failure codes, specifically confirming that the DTC U028400 does not return.

Required Parts

To address the Active Air Flap (AAF) actuator issue, the following updated parts are required:

• Active Air Flap (AAF) Actuator, Left Hand (LH): Part Number 86989-G1000 QQH (supersedes 86989-G1000)
• Active Air Flap (AAF) Actuator, Right Hand (RH): Part Number 86999-G1000 QQH (supersedes 86999-G1000)

Owner Action

If your 2022 Hyundai Ioniq 5 is experiencing "AAF warning signs" or has the diagnostic trouble code U028400 stored, you should contact an IONIQ certified Hyundai dealership to schedule an inspection. This service campaign, identified as 23-01-075H, involves the replacement of the Active Air Flap (AAF) actuator and must be performed by qualified technicians. The repair is covered under warranty as a campaign. Ensure the dealership is aware of the specific campaign number when scheduling your service for the Hyundai Ioniq 5 AAF actuator.

Source: NHTSA ID: 10243363