Is the i6 Cabin air filter design defect a mold hazard?

ZeroDay · Nov 9, 2024

I experienced a recurrent chemical smell in the cabin of my Ioniq 6 and decided to replace the cabin air filter to see if that would help. When I removed the filter I was shocked to find that it was covered in black mold on the bottom side (cabin side). There was also visible rust on the fan located beneath the filter.

Looking online I found a post in the Ioniq 6 subreddit about a known issue that has been featured in a Korean TV Report published a year ago that looks identical to my experience, right down to the rust on the fan. Apparently the filter can get wet when it rains or you use the car wash. I hand-wash my car so it is definitely rain that is an issue in this case.

I picked up a few more filters and plan on checking the filter every couple of weeks and documenting what I find. The black mold had me very concerned and I'm hoping that it doesn't appear again.

The filter is there to prevent mold, pollen, dust and other respiratory hazards from entering the cabin, not to act as a damp mold growth medium so the air system can blow mold spores in your face every time you use the AC. The filter was also completely compromised, so it probably wasn't doing much filtering.

As someone with mold allergies it infuriates me that Hyundai has known about this issue for at least a year and has not issued any warnings or remedies to customers.

ctromley · Nov 9, 2024

I had not heard about this issue until now. So I suspect it is not widespread.

As a product development engineer myself I understand that words matter. At this point we have no idea if this is a "design defect" (a problem the engineers should have foreseen and designed around) as you say, or an assembly/process error or a supplier quality issue. Until you can find exactly where and how moisture is entering - in the apparently very few instances where that happens - that will remain unclear. If that info is known, a quick DIY fix might be possible.*

EVs are more prone to funky odors in their HVAC systems than ICEVs. It's a well-known issue in Teslas. Isn't there an 'auto dehumidify' setting on the climate screen that would serve to dry out a soaked filter element? I seem to recall questions from new owners about the HVAC system running at odd times, and this would be a good reason for it.

I'm not trying to minimize the issue. I have mold allergies too. All I'm suggesting is to keep the discussion focused and in perspective. My experience differs, in that I've driven in the rain plenty, have never had any issue with HVAC and have 'auto dehumidify' set to OFF.

* One issue I have known about but have yet to address, is mice finding a way into the HVAC system and building a nest on the cabin filter. The entry from outside to inside is a port in the unibody structure in the trunk area, which is accessible once some plastic trim is removed. The fix is to put some 1/4" mesh galvanized steel hardware cloth over the port (just stick it on with silicone adhesive).

Seems to me that's a pretty likely entry point for water too, in which case I'd put a little deflector at the top edge of the port as well (made with aluminum flashing, thin enough that you can cut it with scissors, also attached with silicone adhesive), to direct water away from it. Shouldn't need to be big, just enough to get water to move away from the port instead of down into it.

When I get around to it I will do both (maybe even shoot some pics and post a how-to), though at this point we don't know if in fact that is where the water is entering. If anyone has reliable information on that, please share.

ZeroDay · Nov 9, 2024

Great point re: design defect. I had assumed it was present on all i6's based on the Korean TV report, but that isn't proven.

Would it be possible to get a photo of the air inlet port or the trim that needs to be removed to access it?

Is the i6 Cabin air filter design defect a mold hazard?

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