22-01-081H

GROUP
NUMBER
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
22-01-081H
MODEL(S)
OCTOBER 2022
NEXO (FE)
INLET FITTING VALVE REPLACEMENT
(CAMPAIGN T9B)
 IMPORTANT
*** Dealer Stock and Retail Vehicles ***
Dealers must perform this campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the "Vehicle Information” screen (VIS) via WEBDCS to identify open campaigns.
Description: Certain 2019-2021MY NEXO (FE) vehicles may exhibit a micro-leak in the inlet fitting
valve area caused by a part that is out of specification. This bulletin outlines the procedure to replace
each Inlet Fitting Valve on all three storage tanks.
STUI
This TSB includes STUI pictures as a requirement. Where indicated, please include a copy
of the RO or last 6 digits of the VIN and date of repair on a piece of paper. Ensure the VIN
and date of repair are clearly visible. Finally, please ensure all captured pictures are
completed according to the steps in this TSB and uploaded to STUI. All claims submitted
that have illegible, incomplete, missing, or incorrect picture(s) are subject to debit.
Applicable Vehicles: Certain 2019MY ~ 2021MY NEXO (FE) vehicles.
NOTICE
•
The TSB repair procedure MUST be performed at an authorized Hyundai NEXO fuel cell
vehicle dealer and by a Hyundai Expert (or above level) technician who has successfully
completed the Fuel Cell Electric Vehicle Training Instructor Led Training course
(SVCHFCEVTRAIN222_1097).
•
Refer to OSHA standard 1910.137 - Electrical Protective Equipment for PPE inspection and
testing requirements and the NEXO shop manual for PPE usage.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
Parts Information:
IMAGE
PART NUMBER
PART NAME
REMARKS
1KIT
One Inlet fitting valve for each
storage tank (3 total)
Suction nozzle 1EA
INLET FITTING VALVE
35994-M5001QQH
1 tube can be used for about
30 vehicles
Sealant Threebond 1211
21451-33T02QQH
Hydrogen Leak Detector
SNOOP RC Leak check
fluid
Part of Dealer Nexo SST Kit
In case the Hydrogen Leak
Detector does not work.
Snoop RC
Suction Tool
Supplied Directly
09356-M5100
Warranty Information:
OP
CODE
OP
SUBLET
TIME
OPERATION
If - Hydrogen tank pressure is 1,100 PSI
or less and fuel supply lines are
depressurized (i.e. already performed via
20D007R1
separate repair/TSB/campaign).
Then - perform INLET FITTING VALVE
REPLACEMENT (3EA)
1.1
M/H
$1.10
If - Hydrogen tank pressure is 1,100 PSI
or less (i.e. customer drove in with low
fuel) and fuel supply lines need
20D007R2
depressurization. Then - depressurize
fuel supply lines and perform INLET
FITTING VALVE REPLACEMENT (3EA)
1.5
M/H
$151.10
If - Hydrogen tank pressure is 1,101 PSI
or more. Then - Defuel (vent) tanks to
2.3
20D007R3 1,100 PSI or less and depressurize fuel
M/H
supply lines and perform: INLET FITTING
VALVE REPLACEMENT (3EA)
$151.10
TSB #: 22-01-081H
CAUSAL
PART
35994M5001QQH
NATURE CAUSE
CODE
CODE
B21
ZZ1
Page 2 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
NOTE 1: Submit claim on Campaign Claim Entry Screen
NOTE 2: Op Code 20D007R1 accounts for the related defueling (venting), depressurizing fuel
supply lines, and refueling of vehicle costs being covered via a separate repair claim outside of
this TSB.
NOTE 3: Op Codes 20D007R2 and 20D007R3 include $150.00 for transportation of the vehicle
to the fueling station ($50) and fuel to refuel vehicle ($100).
Please DO NOT submit a separate claim with duplicate labor or sublet. If defueling/refueling is
required for overlapping repairs/campaigns, submit the applicable labor operation for
defueling/refueling on ONLY ONE of the claims.
NOTE 4: All Op Codes include $1.10 for Threebond Sealant per vehicle.
NOTE 5: If a part that is not covered by this campaign needs replacement while performing this
campaign, and the affected part is still under warranty, submit a separate claim using the same
repair order. If the part is out of warranty, submit a prior approval request for goodwill
consideration prior to the work.
NOTE 6: The incident parts are subject to callback through the normal Warranty Technical
Center (WTC) parts return process. Claim is subject to debit if the part is requested and not
returned.
NOTE 7: Claim must include STUI pictures that are clearly visible along with a piece of paper
displaying the last 6 digits of the VIN and date of the procedure. Claims submitted with
illegible, incomplete, missing or incorrect pictures are subject to debit.
NOTICE
•
Be sure to check vehicle for outstanding campaigns requiring defueling and perform all
repairs.
TSB #: 22-01-081H
Page 3 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
SUBJECT:
INLET FITTING VALVE REPLACEMENT
Review TSB, ensure all parts and
tools are available to perform the
procedure.
Defuel tanks to 1,100 PSI (7.58 Mpa)*
NO
Is tank pressure
less than or equal to 1,100
PSI (7.58 MPa)
YES
Depressurize fuel supply lines
Depressurize fuel supply lines
Perform Inlet Fitting Valve Procedure
Perform Inlet Fitting Valve Procedure
Repair leak**
NO PASS
Leak check
PASS
Refuel hydrogen tanks
Repair leak**
Depressurize fuel supply lines
Defuel tanks to 1,100 PSI (7.58 Mpa)*
NO PASS
Leak check
PASS
Reinstall
undercovers
STUI photo(s) are required where indicated by STUI camera icon
*Refer to TSB 22-FL-005H when defueling the hydrogen tanks
**Refer to shop manual to perform leak check and repair leaks:
Nexo (FE) > 2019 > 113KW > Hydrogen Storage System > Repair
Procedures> Hydrogen Gas Leak Test > For Hydrogen Storage System
(HSS)
TSB #: 22-01-081H
End of
procedure
Page 4 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
SERVICE PROCEDURE: Depleting Residual Fuel Supply Pressure & Defueling
1.
Place the vehicle in READY mode using the
START / STOP push button. Photograph the fuel
gauge level and a paper showing the last 6 digits
of the VIN or RO #, and the date of defueling.
Similar to the photo to the right.
STUI
Using STUI, photograph the fuel gauge.
Include in the photos a piece of paper
containing the last 6 digits of the VIN or
the RO #, and the date of the defueling.
Ensure the photo is in focus and captures
the fuel gauge display, odometer, and
note. Upload the photo to STUI.
2.
Connect the GDS-M, select the HMU, and then
confirm the storage tank pressure.
3.
If storage tank pressure is less than 1,100 PSI,
then deplete residual fuel supply pressure by
referring to TSB 22-FL-005H—VENTING NEXO
FUEL CELL ELECTRIC VEHICLES or the latest
version.
4.
If storage tank pressure is greater than 1,100
PSI, then defuel storage tanks to less than 1,100
PSI and deplete residual fuel supply pressure by
referring to TSB 22-FL-005H—VENTING NEXO
FUEL CELL ELECTRIC VEHICLES or the latest
version.
TSB #: 22-01-081H
Icon illuminates when the
vehicle is in READY mode.
Page 5 of 18
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1.
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
12 Volt and High Voltage Circuit Disconnection
In the rear cargo area, remove the floorboard and
cargo tray to access the 12 volt battery connector
and high voltage battery Safety Plug.
TSB #: 22-01-081H
Page 6 of 18
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SUBJECT:
2.
Disconnect the 12 volt battery negative (-) connector.
!
3.
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
WARNING
•
Electrocution hazard - Refer to the shop manual - Battery Control System > High
Voltage Battery Handling Guide and follow the High Voltage Shut-off Procedure.
•
Before performing the service procedure, ensure proper Personal Protection
Equipment (PPE) is worn to prevent injury. Verify PPE is not expired and in proper
working condition.
Remove the metal shield to access the High Voltage
Safety Plug.
TSB #: 22-01-081H
Page 7 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
4.
Follow A-D below to remove the orange high voltage
safety plug.
Store the removed safety plug in a secure location
outside and away from the vehicle.
5.
Wait 5+ minutes to allow the high voltage system
capacitor to discharge.
6.
Open the hood. Remove the junction box trim and
cover.
High voltage junction box cover: Assembly bolt
torque: 9.8 -~11.8 N.m
(1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft
Safety Plug Removal
Junction Box Trim
HVJB Cover
TSB #: 22-01-081H
Page 8 of 18
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7.
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
Using a Digital Volt Ohm Meter (DVOM), measure
the voltage across the inverter positive and negative
bus bar terminals to inspect for capacitor discharge.
If the measured voltage is below 30V, the High
Voltage Circuit is properly shut down.
!
•
DANGER
The High Voltage Junction Box
(HVJB) may be electrically energized
up to 450 volts.
Service Procedure:
1. Raise the vehicle a lift according to the Service
Manual.
2. Remove the floor undercover (A) after removing the
fastening bolts.
t
o
p
t
r
o
e
p
v
r
e
e
n
Measure
Voltage
v
Here
t
e
E
n
C
t
M E
d
C
a
M
m d
a
a
g
m
e
a
+
g
e
Tightening Torque:
5.8~8.7 lb-ft. (0.8 ~1.2 kgf.m, 7.8 ∼ 11.8 N.m)
TSB #: 22-01-081H
Page 9 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
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3. Remove the rear hydrogen tank undercover (A) after
removing the fastening bolts.
Tightening Torque:
7.4 ∼ 9.9 N.m. (0.75 ~ 1.01 kgf.m, 5.4 ∼ 7.3 Ib.f-ft)
4. Close the manual valves on all 3 hydrogen tanks.
Using a 6mm Allen wrench turn the manual valve
clockwise until it stops.
Exceeding closing torque specification, may damage
the manual valve.
Closing Torque:
3.6 ~ 7.2 lb-ft (4.9 ~ 9.8 Nm)
NOTICE
•
Some components of the manual valve
may be damaged if over-torqued.
TSB #: 22-01-081H
Page 10 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
5. Loosen the fuel supply pipe and remove the inlet
fitting valve using a socket wrench.
Tightening Torque: Fuel supply pipe
32.4∼38.3 N.m. (3.3~3.9 kgf.m, 23.9∼28.2 Ib.f-ft)
Tightening Torque: Inlet fitting valve
98.1 N.m. (10 kgf.m, 72.4 Ib.f-ft)
NOTICE
•
•
The filter and the O-ring above the inlet
fitting valve may fall out of the tank
valve assembly while removing the
inlet fitting valve. If separated, keep the
parts clean until they are reinstalled.
If any foreign substance enters the
filter or the O-ring, it may disturb the
seal of the valve.
* Assembly order:
Tank valve – O-ring – Filter – O-ring – Inlet fitting
valve.
TSB #: 22-01-081H
Page 11 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
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6. Check the top of the original Inlet Fitting Valve to be
sure the internal O-ring is in place. If it is not, check
inside the Inlet Fitting Valve threaded opening for
the O-ring, if it is present, gently remove it from the
filter with a pick.
NOTICE
•
If the old internal O-ring is left on the
filter in the threaded opening when
installing the new Inlet Fitting Valve, a
leak can occur.
If O-ring is not
inside the original
Inlet Fitting Valve,
then check for Oring on the filter
7. After removing each fuel supply line, cover the open
end with a clean rag to prevent debris from entering
the line.
8. After removing the valve, clean the sealant from the
threads in the area shown using an appropriate tool
such as a pick or razor blade.
TSB #: 22-01-081H
Page 12 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
9. Attach an air hose to the suction tool. Check the tool
has good suction at the end of the hose and the
suction works properly while turning on and off. Use
the tool to suction any foreign substance from the
threads.
10. Remove any foreign material from the screw threads.
Insert the suction hose only about 1cm into the thread
opening. (Suction should be performed around 30
seconds.)
Filter
THREADS
NOTICE
•
•
Use care not to dislodge the filter and
upper O-ring. The separated filter and
O-ring may be contaminated or lost.
See page 11, step 5 for illustration.
SUCTION HOSE
11. Remove an inlet fitting valve from its vacuum
package. Each valve is packaged separately.
NOTICE
•
Do not touch the O-ring installed on
the inlet fitting valve with your hand.
Be careful not to contaminate the inlet
fitting valve when you take it out of the
vacuum package.
TSB #: 22-01-081H
Page 13 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
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12. Be sure to use the new Inlet Fitting Valve and do not
confuse it with the old Inlet Fitting Valve. The new
valve has stamped markings along the wrench
flange area and the old valve does not. See image
for comparison.
NEW
OLD
13. The correct assembly of the reused parts and the new
parts are shown.
NOTICE
•
•
The filter and the O-ring above the inlet
fitting valve may fall out of the tank
valve assembly while removing the
inlet fitting valve. If separated, keep the
parts clean until they are reinstalled.
If any foreign substance enters the
filter or the O-ring, it may disturb the
seal of the valve.
14. Install a new inlet fitting valve.
Hand-tighten the fuel supply pipe nut onto the inlet
fitting valve and then torque the pipe nut to
specification.
Tightening Torque: Inlet fitting valve
98.1 N.m. (10 kgf.m, 72.4 Ib.f-ft)
Tightening Torque: Fuel supply pipe
32.4∼38.3 N.m. (3.3~3.9 kgf.m, 23.9∼28.2 Ib.f-ft)
NOTICE
•
•
Ensure the filter is in place before assembling
the new Inlet Fitting Valve to the Tank Valve
assembly.
Verify the mating surfaces of the fuel tube and
inlet fitting valve are clean before assembling
them together. If any foreign substance enters
the seal, it may disturb the seal of the valve.
TSB #: 22-01-081H
Page 14 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
* Assembly order:
Tank valve – O-ring – Filter – O-ring – Inlet
fitting valve.
TSB #: 22-01-081H
Page 15 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
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15. After replacing the valve, apply sealant at the
location shown. Close the cap after applying sealant
to prevent clogging.
NOTICE
•
•
Apply the sealant by using the nozzle
included in the box.
Wait 24 hours before washing the car
to allow sealant to cure.
NOTICE
16.
•
Use gas detector or Snoop liquid leak
detector to test if there is any gas
leakage.
•
-Do not apply Snoop liquid on the part
where the sealant is applied.
•
-If there is any leakage on the part
where the sealant is applied, the
sealant may inflate.
STUI
Using STUI, take THREE pictures; one
picture for each of the three Inlet Fitting
Valves replaced. (Similar to the photo to
the right)
Include in the photo a piece of paper
containing the last 6 digits of the VIN or
the RO #, the date of the installation of
the new Inlet Fitting Valve. Ensure the
image is in focus and includes the Inlet
Fitting Valve, the note, and the lettering
on the tank valve. Upload the photo to
STUI.
TSB #: 22-01-081H
Page 16 of 18
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SUBJECT:
INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
17. Open the manual valves on all 3 hydrogen tanks.
Using a 6mm Allen wrench turn the manual valve
counter-clockwise until it stops then rotate manual
valve one half turn clockwise.
Exceeding opening torque specification, may
damage the manual valve.
Opening Torque:
3.6 ~ 7.2 lb-ft (4.9 ~ 9.8 Nm)
NOTICE
•
Some components of the manual valve
may be damaged if over-torqued.
18. Reconnect the 12-volt and High-voltage batteries. Refer to page 6.
19. With the vehicle in ready mode, perform a leak check of lines, fittings and components removed
and/or replaced, using a Hydrogen leak detector.
Refer to the shop manual:
Nexo (FE) > 2019-2021 > 113KW > Hydrogen Storage System > Repair Procedures>
Hydrogen Gas Leak Test > For Hydrogen Storage System (HSS)
If no leak is found, then proceed to the next step. Do not reinstall the under covers until final leak
check is performed.
If a leak is found. Refer to TSB 22-FL-005H—VENTING NEXO FUEL CELL ELECTRIC
VEHICLES to perfom “Preparation for Replacement of Hydrogen Components” and “Depleting
Residual Fuel Supply Pressure”. Repair the leak(s), then perform this step again until no leak is
found.
20. Refuel hydrogen storage tanks to full at a local hydrogen station.
Refer to the station websites below to confirm station availability before driving or towing vehicle to
the station:
• https://cafcp.org/stationmap
• https://h2-ca.com/
TSB #: 22-01-081H
Page 17 of 18
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INLET FITTING VALVE REPLACEMENT (SERVICE CAMPAIGN T9B)
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21. After refueling the vehicle, with the key in the ON
positon, photograph the fuel gauge level and a
paper showing the last six digits of the VIN or RO #,
and the date of refueling. Similar to the photo to the
right.
STUI
Using STUI, photograph the fuel gauge.
Include in the photo a piece of paper
containing the last 6 digits of the VIN or
the RO #, the date of the refueling.
Ensure the fuel gauge display,
odometer, and note are captured and in
focus. Upload the photo to STUI.
22. After the Hydrogen tanks have been refueled. Put the vehicle on a lift and place the vehicle into
READY mode using the PBSS. Perform a leak check of hydrogen fuel components that were
replaced, using a Hydrogen leak detector.
Refer to the shop manual:
Nexo (FE) > 2019-2021 > 113KW > Hydrogen Storage System > Repair Procedures>
Hydrogen Gas Leak Test > For Hydrogen Storage System (HSS)
23. If a leak is found. Refer to TSB 22-FL-005H—VENTING NEXO FUEL CELL ELECTRIC
VEHICLES and defuel tanks to 1,100 PSI or less. “Preparation for Replacement of Hydrogen
Components” and “Depleting Residual Fuel Supply Pressure”. Repair the leak(s), then perform
steps 19-22 on pages 17 and 18 again until no leak is found.
24. If no leak is found, then replace the undercovers.
25. The procedure is now complete
TSB #: 22-01-081H
Page 18 of 18
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