Technical Service Bulletin
SUBJECT:

GROUP
CAMPAIGN

NUMBER
18-01-003

DATE

MODEL(S)

JANUARY, 2018

IONIQ ELECTRIC (AE EV)

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR
REPLACEMENT (SERVICE CAMPAIGN T2T)

 IMPORTANT

*** Dealer Stock and Retail Vehicles ***
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America's "Warranty Vehicle
Information" screen via WEBDCS to identify open Campaigns.
Description: Some Ioniq EV (AE EV) vehicles may experience the charging connector lock/unlock
actuator malfunction, which may cause:
 The charging connector does not remain locked when the charger is inserted into the charging
port.
 The charging connector cannot be removed from the vehicle charging port.
This bulletin provides the service procedure to replace the charging connector lock/unlock actuator.

Applicable Vehicles: Certain 2017 Ioniq Electric (AE EV)
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

SUBJECT:

Parts Information:
PART NAME

PART NUMBER

Inlet Actuator

91999-G7310QQH

PART IMAGE

QTY.

1

Warranty Information:
MODEL

OP. CODE

Ioniq Electric
70C095R0
(AE EV)

OPERATION

OP. TIME

CAUSAL PART

INLET ACTUATOR
REPLACEMENT

1.0 M/H

91886-G7600

NATURE CAUSE
Q57

ZZ3

NOTE 1: Submit Claim on Campaign Claim Entry Screen
NOTE 2: If a part is found in need of replacement while performing Service Campaign T2T and the
affected part is still under warranty, submit a separate warranty claim using the same Repair
Order. If the affected part is out of warranty, submit a Prior Approval Request for goodwill
consideration prior to performing the work.

TSB #: 18-01-003

Page 2 of 8

SUBJECT:

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

Service Procedure:
CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
!

WARNING

Be sure to read and follow the “General Safety Information and Caution” notice before doing
any work related with the high voltage system. Failure to follow the safety guidelines may
result in serious electrical injuries.
1.

Align the vehicle onto the lift. Do not lift the
vehicle up.

2.

If applicable, record the customer’s radio preset
stations for AM/FM/XM.

3.

Open charger door by pressing the release
buttons on the dash.
Open tailgate by pressing the release buttons on
the tailgate.

4.

Pull hood release to open the hood to access
the auxiliary battery.

5.

Disconnect the negative (-) cable on the
auxiliary 12 V battery.
Negative battery terminal tightening torque:
3.0~4.4 lb-ft (4.0~6.0 Nm, 0.4~0.6 kgf.m)

TSB #: 18-01-003

Page 3 of 8

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

SUBJECT:

6.

Remove the trunk covers.
Remove the safety plug cover by using a Phillips
screwdriver to remove the clip located in the
picture to the right.

7.

Wear insulated protective gloves and disconnect
the high voltage safety plug by following the
illustration steps shown to the right.

!

CAUTION

Per the EV “General Safety Information and
Caution Notice”, wear insulated safety
gloves when working on high voltage
components that have an orange connector
and cable color.

NOTE: Step 2 is pushing the yellow tab inward
and then lift.
Ensure the insulated safety gloves are not
expired by checking the stamped date on the
gloves.

Bosch Part
Number
J-48755-11H

To order a new set of insulated safety gloves
contact Bosch at 1-866-539-4248. Refer to the
table on the right for the part number
information.

(Medium)

J-48755-12H
(Large)

Description

Image

Insulated
Leather Safety
Gloves
Insulated
Leather Safety
Gloves

Refer to https://www.grainger.com/content/qtelectrical-safety-gloves-inspection-262 for
electrical safety gloves inspection information.
TSB #: 18-01-003

Page 4 of 8

SUBJECT:

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

8.

Wait 5 minutes to allow the high voltage battery
capacitor to fully discharge.

9.

Remove the three 10mm nuts holding the
charger port and pull the charger port plugs.
Quick charging port mounting bolt
tightening torque:
8.0~10.1 lb-ft (10.8~13.7 Nm, 1.1~1.4 kgf.m)

10. Lift the vehicle to comfortable working height.

11. Remove the rear driver’s side wheel by
removing the 5 lug nuts.
Lug nut tightening torque:
79.6~94.0 lb-ft (107.9~127.5 Nm, 11.0~13.0
kgf.m)

TSB #: 18-01-003

Page 5 of 8

SUBJECT:

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

12. Remove the wheel well liner by removing the
three types of fasteners located in the picture to
the right.

13. Remove a 10mm bolt and a 10mm nut to loosen
the charging wiring harnesses.
Quick charging port bracket mounting
nut/bolt tightening torque:
7.2~8.7 lb-ft (9.8~11.8 Nm, 1.0~1.2 kgf.m)

Loosen the harnesses by pulling them out of the
body mounting screws.

TSB #: 18-01-003

Body mounting screw

Page 6 of 8

SUBJECT:

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

14. Carefully pull the charging port away from the
fender and wiggle downward to release the
charging port.

15. Disconnect the connector from the charging
lock/unlock actuator.

16. Use a T15 Torx screwdriver to remove the two
screws holding the charging lock/unlock
actuator.

TSB #: 18-01-003

Page 7 of 8

SUBJECT:

CHARGING CONNECTOR LOCK/UNLOCK ACTUATOR REPLACEMENT
(SERVICE CAMPAIGN T2T)

17. Remove the cable from the charging lock/unlock
actuator arm.

18. Remove the red rubber seal from the old part
and place it onto the new part.

Rubber Seal

Replace the charging lock/unlock actuator with
the new part.

19. Reinstall all removed parts in reverse order.
20. Confirm if the charging port locks/unlocks and if
charging function is operating by checking the
vehicle’s charging status.

TSB #: 18-01-003

Page 8 of 8