2022-2025 Hyundai Ioniq 5/6 DC Pin Cap Replacement TSB 25-EV-003H

Hyundai has released Technical Service Bulletin (TSB) 25-EV-003H to address a potential issue with missing Inlet 5-Pin Combo DC insulation caps, commonly referred to as DC pin caps, on certain electric vehicles. This bulletin applies to 2022-2024 model year (MY) IONIQ 5 (NE EV), 2023-2024 MY IONIQ 6 (CE EV), and 2025 MY IONIQ 5 N (NE EV N) vehicles.

The absence of these DC pin caps can lead to damage to the vehicle's charge port if not properly replaced. This TSB provides detailed instructions for certified Hyundai technicians to replace the missing caps, ensuring the longevity and proper function of the charging system.

Symptoms

The primary symptom addressed by this TSB is the physical absence of the DC pin caps within the vehicle's charge port. While this might not immediately manifest as a driving issue, the missing caps expose the charge port's internal components. Over time, this exposure can result in damage to the charge port, potentially affecting the vehicle's ability to charge properly.

Important Warnings

Owners and technicians should be aware of critical advisories related to this service bulletin:

• Certified Dealer Requirement: "To avoid any potential damage to IONIQ vehicles, IONIQ repairs can only be performed at IONIQ certified dealers." This ensures that specialized technicians with the correct tools and training handle the repair.
• Safety During Removal: When removing existing caps, technicians are warned: "Replace one cap at a time to avoid the risk of inserting pliers into both sides of the DC charge port simultaneously. Doing so may cause personal injury or damage the vehicle."
• Careful Cap Removal: A specific notice states: "Pull the DC pin cap straight out to avoid damage to the pin." Additionally, when using needle-nose pliers, technicians must "ONLY grip the plastic part of the pin" to prevent damage to the charge port.

Repair Procedure Summary

The repair procedure outlined in TSB 25-EV-003H is straightforward and aims to securely install new DC pin caps. The process begins with the technician opening the charging door and visually inspecting the charge port to confirm the presence of any missing DC pin caps. Digital documentation is a crucial step, requiring a photograph of the missing caps along with the last six digits of the vehicle's VIN and the date of repair.

If existing caps need to be removed, needle-nose pliers are used, with strict instructions to grip only the plastic part of the pin to prevent damage. New DC pin caps, identified by part number 91691-GI031FFF, are then prepared for installation. Each new cap is inserted into the specialized DC Pin Cap Installation Tool, part number 91961-G1531FFF, ensuring the flat surface faces inside the tool.

The installation tool is then aligned with the DC post in the charge port, carefully positioning the pin cap. A rubber mallet is used to gently tap the installation tool three to four times, which securely seats the pin cap onto the post. This process is repeated for any additional missing DC pin caps. The estimated operation time for this repair is 0.3 hours, identified by operation code 91691Q0A.

Required Tools or Parts

To perform the DC pin caps replacement, specific parts and a special service tool are required:

• DC Pin Caps: Part Number 91691-GI031FFF. These caps are supplied in bags containing three caps each.
• DC Pin Cap Installation Tool: Part Number 91961-G1531FFF. Each IONIQ certified dealer received one unit during the initial TSB release, and additional units can be ordered through the normal parts process.

Owner Action

If you own a 2022-2025 Hyundai Ioniq 5, Ioniq 6, or Ioniq 5 N, it is recommended to visually inspect your vehicle's charge port for any missing Inlet 5-Pin Combo DC insulation caps. If you identify that any of these DC pin caps are missing, you should contact an authorized and IONIQ certified Hyundai dealer. They will be able to perform the necessary inspection and replacement service under TSB 25-EV-003H. This repair is covered under normal warranty conditions.

NHTSA ID: 11020938