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December 14, 2022 NHTSA CAMPAIGN NUMBER: 22V926000
High-Voltage Battery May Overheat
The high-voltage battery overheating increases the risk of a fire.
NHTSA Campaign Number: 22V926
Manufacturer Polestar Automotive USA, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 66
Summary
Polestar Automotive USA, Inc. (Polestar) is recalling certain 2020-2021 Polestar 1 vehicles. Defective high-voltage battery cells may cause the battery to overheat when fully charged.
Remedy
Dealers will replace the high-voltage battery cells, free of charge. Remedy parts are expected to become ready by June 2023. As an interim repair, owners will need to take their vehicle to a dealership for a software update. Interim notices were mailed January 31, 2023. Owners may contact Polestar customer service at 1-800-806-2504. Polestar’s number for this recall is R10202. Note: This recall has been superseded by Recall 23V361 (R102316). Any vehicle that received the interim repair under Recall 22V926 (R10202) will still need to have the remedy for 23V361 (R102316) performed.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
RECALL R10202 DESCRIPTION
Polestar Automotive USA on behalf of Polestar Performance AB, have decided to launch Recall R10202 on certain model year 2020 – 2021 Polestar 1 vehicles.
Polestar investigations have shown a potential issue with the high-voltage battery in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged.
There is a potential risk of a fire when the battery is fully charged.
To remedy concerned vehicles, Polestar will as an interim solution, download a software update to the vehicle to minimize the risk and to ensure that the vehicle can be charged as normal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine.
The permanent remedy is to replace all defective hardware. Polestar is now preparing a corrective action for the affected vehicles and the customers will be notified when parts are available through a second Recall. Polestar estimates the start date for repairs to begin at the end of quarter 2, 2023.
WHAT SHOULD YOUR CUSTOMERS DO NOW?
We have no reports of incidents related to the issue; however, we encourage customers to contact their Service Point and have this repair completed as soon as possible.
VEHICLES INVOLVED
NOTE: SERVICE POINT MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THE REPAIR FOR THIS RECALL.
Vehicle eligibility must be confirmed:
- Vehicle Inquiry – Warranty Vehicle Inquiry where the message “Recall R10202 PHEV Battery” will appear for eligible vehicles, F4=History from the main Inquiry menu must be selected to confirm Recall R10202 has not been completed. Eligibility can also be confirmed in VIDA.
All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed.
PORT VEHICLES
NOT all eligible vehicles arriving from the ports will have this recall completed. Vehicle eligibility must be confirmed as outlined in Step B. above.
PARTS / PARTS RETURN
Please refer to Parts Bulletin R10202. No parts to be returned required for this recall.
OWNER NOTIFICATION
An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar Service Point and request an appointment to have this repair completed.
VEHICLES IN INVENTORY
New Vehicles in Inventory
It is a violation of federal law for a retailer to deliver any new Polestar that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle.
Correct all vehicles in your new vehicle inventory before delivery.
Used Vehicles in Inventory
Polestar is ordering the stop-delivery of affected vehicles in auction and dealer inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with our commitment to safety.
What does this mean for customers?
Customers will not be able to take delivery of affected vehicles until the recall has been completed.
SERVICE POINT RESPONSIBILITY
All vehicles qualifying for this recall must be repaired prior to a customer taking possession of the vehicle.
TECHNICIAN COMPETENCY REQUIREMENT
The technician competency requirement for this campaign repair is: Level 2 – Certified Tech.
Chronology :
Condition considered critical by Critical Management Team 09.12.2022; Field Service Action decision confirmed by Polestar 12.14.2022; Condition detected by market; Number of vehicle reports with the condition reported from National Sales Company 0; Total number of cars included in vehicle reports concerning this condition 0; Implementation date of Field Service Action 12.15.2022; Extended chronology of events; Volvo Cars inform Polestar regarding potentially affected batteries 09.07.2022; Start technical investigation regarding potential field service action 09.21.2022; Compare PS1 cell production date with VCC population; Investigate/compare battery usage overtime; Compare hardware differences between PS1 and SPA PHEV; Considered as a critical concern by CCMT 12.14.2022; Field Service Action decision confirmed by Volvo Car Corporation 12.15.2022.
R102316 – PHEV Battery – 2020-2021 Polestar 1
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
POLESTAR | POLESTAR 1 | 2020-2021 |
6 Associated Documents
Defect Notice 573 Report
RCLRPT-22V926-3221.PDF 215.632KB
Recall Acknowledgement
RCAK-22V926-1194.pdf 645.147KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V926-7102.pdf 145.353KB
Remedy Instructions and TSB
RCRIT-22V926-3891.pdf 461.128KB
Remedy Instructions and TSB
RCRIT-22V926-1999.pdf 433.803KB
Owner Notification Letter(Part 577)
RCONL-22V926-0489.pdf 574.299KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V926&docType=RCL
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SEOCONTENT-START
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-926 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Polestar Automotive USA, Inc. Submission Date : DEC 14, 2022 NHTSA Recall No. : 22V-926 Manufacturer Recall No. : R10202 Manufacturer Information : Manufacturer Name : Polestar Automotive USA, Inc. Address : 1 Volvo Drive ROCKLEIGH NJ 07647 Company phone : 999 Population : Number of potentially involved : 66 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2021 Polestar 1 Vehicle Type : LIGHT VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : Concerned vehicles are certain 2020-2021 Polestar 1 vehicles from start of production for PHEV vehicles with Forever Energy batteries produced in China. The end breakpoint is based on Computed Tomography scans, battery tear down and physical testing. A fault in the battery cells may cause a thermal event or fire when the high-voltage battery is fully charged. This is a suppliers’ responsibility due to a manufacturing defect which occurred during a specific production period at the battery supplier’s production line for battery cells. 66 Vehicles in the U.S. are affected. Production Dates : SEP 11, 2019 – MAY 12, 2021 VIN Range 1 : Begin : LYVPKBDTDLB000109 End : LPSBE0YL8MB001019 ✔ Not sequential Description of Defect : Description of the Defect : Polestar investigations has shown a potential issue with the high-voltage battery in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : There is a risk of a potential fire when the high-voltage battery is fully charged. Description of the Cause : The root cause is a manufacturing defect which occurred during a specific production period at the battery supplier’s production line for battery cells. Identification of Any Warning that can Occur : The customer will receive no warnings prior to overheating of battery cells. Part 573 Safety Recall Report 22V-926 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Forever Energy High-voltage battery cells. Component Description : High-Voltage battery Component Part Number : NR Supplier Identification : Component Manufacturer Name : Zhejiang Forever New Energy Technology C Address : No 589 Longtan Rd. HIGH-TECH INDUSTRY PA Jinhua Foreign States 321000 Country : China Chronology : Condition considered critical by Critical Management Team 09.12.2022; Field Service Action decision confirmed by Polestar 12.14.2022; Condition detected by market; Number of vehicle reports with the condition reported from National Sales Company 0; Total number of cars included in vehicle reports concerning this condition 0; Implementation date of Field Service Action 12.15.2022; Extended chronology of events; Volvo Cars inform Polestar regarding potentially affected batteries 09.07.2022; Start technical investigation regarding potential field service action 09.21.2022; Compare PS1 cell production date with VCC population; Investigate/compare battery usage overtime; Compare hardware differences between PS1 and SPA PHEV; Considered as a critical concern by CCMT 12.14.2022; Field Service Action decision confirmed by Volvo Car Corporation 12.15.2022. Part 573 Safety Recall Report 22V-926 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : To remedy concerned vehicles, Polestar will as an interim solution, download a software update to the vehicle to minimize the risk and to ensure that the vehicle can be charged as normal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine. The permanent remedy is to replace all defective hardware. Polestar is now preparing a corrective action for the affected vehicles and the customers will be notified when parts are available through a second recall. Polestar estimates the start date for repairs to begin at the end of quarter 2, 2023. How Remedy Component Differs from Recalled Component : Concerned vehicles were certain 2020-2021 Polestar 1 vehicles which will receive the updated software update. Identify How/When Recall Condition was Corrected in Production : Production of the Polestar 1 has ended, and the software aspect of this corrective action is an interim solution. Recall Schedule : Description of Recall Schedule : Remedy Notices Planned Dealer Notification Date : DEC 14, 2022 – DEC 14, 2022 Planned Owner Notification Date : DEC 19, 2022 – DEC 23, 2022 * NR – Not Reported
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Polestar Service and Parts Business Quality Bulletin TITLE: Recall R10202: PHEV Battery Model Year 2020-2021 Polestar 1 GROUP: 31 NO: R10202 ISSUING DEPARTMENT: Product, Safety and Compliance CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2022-12-16 STATUS DATE: 2022-12-16 Page 1 of 3 Produced and printed in the USA and available as an electronic document. © Polestar 2022 BULLETIN REFERENCE A. RECALL R10202 DESCRIPTION B. VEHICLES INVOLVED C. PORT VEHICLES D. PARTS INFORMATION/PARTS RETURN E. OWNER NOTIFICATION F. VEHICLES IN INVENTORY G. SERVICE POINT RESPONSIBILITY H. TECHNICIAN COMPETENCY REQUIREMENT I. REIMBURSEMENT PROCEDURES & ALLOWANCE A. RECALL R10202 DESCRIPTION Polestar Automotive USA on behalf of Polestar Performance AB, have decided to launch Recall R10202 on certain model year 2020 – 2021 Polestar 1 vehicles. Polestar investigations have shown a potential issue with the high-voltage battery in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar will as an interim solution, download a software update to the vehicle to minimize the risk and to ensure that the vehicle can be charged as normal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine. Page 2 of 3 2022-12-16 Service Manager Bulletin R10202 The permanent remedy is to replace all defective hardware. Polestar is now preparing a corrective action for the affected vehicles and the customers will be notified when parts are available through a second Recall. Polestar estimates the start date for repairs to begin at the end of quarter 2, 2023. WHAT SHOULD YOUR CUSTOMERS DO NOW? We have no reports of incidents related to the issue; however, we encourage customers to contact their Service Point and have this repair completed as soon as possible. B. VEHICLES INVOLVED NOTE: SERVICE POINT MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THE REPAIR FOR THIS RECALL. Vehicle eligibility must be confirmed: • Vehicle Inquiry – Warranty Vehicle Inquiry where the message “Recall R10202 PHEV Battery” will appear for eligible vehicles, F4=History from the main Inquiry menu must be selected to confirm Recall R10202 has not been completed. Eligibility can also be confirmed in VIDA. All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed. C. PORT VEHICLES NOT all eligible vehicles arriving from the ports will have this recall completed. Vehicle eligibility must be confirmed as outlined in Step B. above. D. PARTS / PARTS RETURN Please refer to Parts Bulletin R10202. No parts to be returned required for this recall. E. OWNER NOTIFICATION An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar Service Point and request an appointment to have this repair completed. F. VEHICLES IN INVENTORY New Vehicles in Inventory It is a violation of federal law for a retailer to deliver any new Polestar that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. Used Vehicles in Inventory Polestar is ordering the stop-delivery of affected vehicles in auction and dealer inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with our commitment to safety. 2022-12-16 Page 3 of 3 Service Manager Bulletin R10202 What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. G. SERVICE POINT RESPONSIBILITY All vehicles qualifying for this recall must be repaired prior to a customer taking possession of the vehicle. H. TECHNICIAN COMPETENCY REQUIREMENT The technician competency requirement for this campaign repair is: Level 2 – Certified Tech. I. REIMBURSEMENT PROCEDURES & ALLOWNACE Recall R10202 claims should be submitted using the LONG FORM application only. Claim Type: R10202 Cause Code: 02 CSC Code: XW Main OP: 99941-3 Failed Part No: 32397350 (BECM 80% fix) Operation Number Repair Description Qty Models Labor Time 99940-2 Software update acc. To QB 1 Polestar 1 0.5 99941-3 Software update acc. To QB 1 Polestar 1 0.2 IMPORTANT NOTE: Software should be downloaded in this order: 1. Total Upgrade. 2. BECM 80% fix. *Labor times provided are current at the time of release and are subject to change: Claims will be paid at the time in effect on the repair date.
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STEVE DEGRAZIO – HEAD OF QUALITY, CAR SERVICE & REPAIR EXPERIENCE, NORTH AMERICA December 15, 2022 Subject: Recall R10202 TO: All U.S and Canadian Sales and Service Points NEW VEHICLES IN RETAILER INVENTORY It is a violation of federal law for a retailer to deliver any new Polestar that is eligible for a recall. Service Points are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a Service Point could result in a civil penalty of up to $22,723 per vehicle. Correct all vehicles in your new vehicle inventory before delivery. USED VEHICLES IN INVENTORY Polestar is ordering the stop-delivery of affected vehicles in auction and inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with Polestar commitment to safety. Additionally, while Federal law does not prohibit the sale of used vehicles with open recalls, the sale of such cars could violate certain state laws and create liability on behalf of the service point. What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. When will this be resolved? Polestar Automotive USA on behalf of Polestar Performance AB, have decided to launch Recall R10202 on certain model year 2020 – 2021 Polestar 1 vehicles. Polestar investigations have shown a potential issue with the high-voltage battery in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar will as an interim solution, download a software update to the vehicle to minimize the risk and to ensure that the vehicle can be charged as normal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine. The permanent remedy is to replace all defective hardware. Polestar is now preparing a corrective action for the affected vehicles and the customers will be notified when parts are available through a second Recall. Polestar estimates the start date for repairs to begin at the end of quarter 2, 2023. Polestar Automotive USA Inc. 777 MacArthur Blvd Page 1 of 2 Mahwah, NJ 07430 Telephone +1-201-981-7066 Vehicle eligibility must be confirmed: • Vehicle Inquiry – Warranty Vehicle Inquiry where the message “Recall R10202 PHEV Battery” will appear for eligible vehicles, F4+History from the main Inquiry menu must be selected to confirm Recall R10202 has not been completed. Eligibility can also be confirmed in VIDA. • Recall R10202 eligible vehicles not yet delivered to end customers must be corrected prior to delivery. All vehicles must be checked for any incomplete Recalls, Service Campaigns, or Service Upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed. OWNER NOTIFICATION An owner notification will be sent out that will notify the owner of this recall instructing them to contact their Polestar Service Point and request an appointment to have this repair completed. PORT VEHICLES NOT all eligible vehicles arriving from the ports will have this recall completed. Vehicle eligibility must be confirmed. PARTS / PARTS RETURN Please refer to Parts Bulletin R10202 which will be released shortly. No parts are required to be returned for this recall. CLAIM SUBMISSION A Quality Bulletin will be released shortly. Please refer to the claim submission information in the Quality Bulletin. SERVICE POINT RESPONSIBILITIES Service Point must perform this recall campaign on eligible vehicles regardless of miles/kilometers or vehicle age. All work performed under this recall is free of charge to the owner. As the safety of our customers is our utmost priority, we are taking full responsibility to ensure the highest quality and safety standards for our cars. If you have questions about this recall or any other field service action, please contact me or any member of our Customer Experience Center. Your cooperation in completing this important recall is greatly appreciated. Best regards, Steve DeGrazio Head of Quality, Car Service & Repair Experience, North America 201-981-7066 Steve.degrazio@polestar.com Page 2 of 2
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Produced and printed in the USA and available as an electronic document. © Polestar 2023 Polestar Service and Parts Business Parts Bulletin TITLE: Recall R10202: PHEV Battery Model Year: 2020-2021 Polestar 1 GROUP: 31 NO: R10202 CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2023-01-09 STATUS DATE: 2023-01-09 Page 1 of 1 Reference Bulletins: QB R10202 Polestar Automotive USA on behalf of Polestar Performance AB, have decided to launch Recall R10202 on certain model year 2020 – 2021 Polestar 1 vehicles. Polestar investigations have shown a potential issue with the high-voltage battery in a limited number of PHEV vehicles due to a manufacturing defect, potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. To remedy concerned vehicles, Polestar will as an interim solution, download a software update to the vehicle to minimize the risk and to ensure that the vehicle can be charged as normal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine. The permanent remedy is to replace all defective hardware. Polestar is now preparing a corrective action for the affected vehicles and the customers will be notified when parts are available through a second Recall. Polestar estimates the start date for repairs to begin at the end of quarter 2, 2023. The following part numbers apply: Part Number Description Qty 32397350 BECM 80% fix 1 32137209 Total Upgrade 1
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Polestar A. Owner 13245 Main St. Any City, US 12345-6789 January 31, 2023 IMPORTANT SAFETY RECALL 1 NHTSA RECA 22V-926 THIS NOTICE APPLIES TO YOUR VEHICLE, VIN: LPSBE0YL6LB000210 Dear Polestar Owner, This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Polestar Performance AB has decided that a defect which relates to motor vehicle safety exists on certain model year 2020-2021 Polestar I vehicles. The reason for RecalJ R10202: Polestar Performance AB investigations have shown a potential issue with the high-voltage battery in certain PHEV vehicles due to a manufacturing defect potentially leading to overheating of the battery cells when the battery is fully charged. There is a potential risk of a fire when the battery is fully charged. What should you do now·? Take your vehicle to an authorized Polestar Service Point and as an interim solution, a software update will be installed, at no cost to vou, to the vehicle to minimize the risk and to ensure that the vehicle can be charged as nonnal. This software update will be an interim solution to prevent the battery to be fully charged, with a reduction of electric driving range as a result, but it does not affect the normal operation of the engine. This interim solution will be completed at no cost to vou and can take up to one hour to complete, however due to service scheduling your Polestar Setvice Point may require your vehicle for a longer period. The interim solution (the software download) will satisfy the requirements of Recall Rl0202. The final solution will be a hardware replacement. When parts become available, Polestar will send you a follow-up letter to schedule a repair, at no cost to you, and update the software once again to bring the electric d1iving range back to 100%. If you no longer own the vehicle described in this letter, please help us to update our records by sending us the updated owner information. Please refer to our contact information in this letter. Please contact: If you have any questions, please contact Polestar Customer Suppoit: 777 MacArthur Blvd. Mahwah, NJ 07430 Or by phone at 1-800-806-2504, Monday – Friday, 8:00 am to 8:00 pm. You may also contact us by going to http://w,vw.polestar.com/us/contact . We have advised the National Highway Traffic Safety Administration (NHTSA) that we are conducting this recall. If you are unable to have this procedure performed without charge, and within a reasonable period of time you may contact the NHTSA Administrator at: National Highway Traffic Safety Administration 1200 New Jersey Avenue, SE. Washington, DC 20590 Or you can call the toll-free Vehicle Safety Hotline at l-888-327-4236 (TTY: l-800-424-9153). You may also go to their website, http://www.safercar.gov. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. To learn more about Polestar safety recalls, visit us at: https ://w\VW .po lesta r.com/us/reca 11-i nformation/ Thank you for being a member of the Polestar family. We hope you will appreciate our efforts to continually provide you with updated information of importance to your safety and the quality of your Polestar I vehicle. Sincerely, Steve DeGrazio Head of Quality, Car Service & Repair Experience, No1th America 201-981-7066 Steve.degrazio@polestar.com
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