22-01-086H

GROUP
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
NOVEMBER 2022
NUMBER
22-01-086H
MODEL(S)
NEXO (FE)
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE
(CAMPAIGN T9C)
 IMPORTANT
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.
Access the “Vehicle Information” screen (VIS) via WEBDCS to identify open campaigns.
Description: In certain 2019-2021MY NEXO (FE) vehicles the hydrogen stack pressure sensors may
have deformation of the thin plate part due to insufficient oil filling during the manufacturing process,
resulting in excessive deviation of the sensor output values and consequent illumination of the MIL
(Malfunction Indicator Light). This bulletin outlines the procedures to inspect and if needed, replace the
hydrogen stack pressure sensors.
Applicable Vehicles: Certain 2019-2021MY NEXO (FE) vehicles.
STUI
This TSB includes STUI pictures as a requirement. Where indicated, please include the last
six digits of the VIN and date of repair on a piece of paper next to the installed sensors.
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.
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:
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Parts Information:
PART NAME
FIGURE
Hydrogen Pressure
Sensor
PART NUMBER
REMARKS
35872-M5100QQH
Two parts per package
Warranty Information:
MODEL
OP CODE
OPERATION
OP
TIME
20D049R1
HYDROGEN
PRESSURE
SENSOR
INSPECTION
0.3 M/H
NEXO
(FE)
CAUSAL PART
NATURE CAUSE
CODE
CODE
35872-M5100QQH
I11
ZZ3
HYDROGEN
PRESSURE
20D049R0
SENSOR
0.7 M/H
INSPECTION AND
REPLACEMENT
NOTE 1: Submit claim on Campaign Claim Entry Screen
NOTE 2: 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 3: 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 4: 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 repair. Claims submitted with illegible,
incomplete, missing or incorrect pictures are subject to debit.
TSB #: 22-01-086H
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HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
i Information
•
Confirm your GDS-M has the most recent software version. If not, connect the GDS-M
Mobile to an Internet port, open the GDS-M home page and select “Internet Update.”
Refer to www.hyundaitechinfo.com if necessary.
•
If you encounter GDS-M related problems, call the GIT Helpline at 888-437-0308.
i Information
•
Perform this procedure outdoors at a designated Hydrogen venting location.
NOTICE
•
•
Damage to the sensor may occur if the metal foil membrane (A) contacts other objects. Do
not touch or allow sensor membrane to contact other objects.
Use extreme care when handling and installing the sensor. Keep protective cap installed
until the sensor is ready to install.
A
Inspection Procedure
1.
Visually inspect the hydrogen pressure sensor.
If the sensors are labeled same as the “After
Improvement” image to the right, then submit
STUI photo of the sensors; the procedure is
complete.
If the sensors have a white label the same as
the “Before Improvement” image to the right,
then submit STUI photo of sensors and proceed
to “Service Procedure” and replace both
sensors with the new parts (35872M5100QQH).
TSB #: 22-01-086H
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2.
3.
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Using a letter size sheet of paper, fold it four (4)
times lengthwise. Place the VIN and inspection
date on the end of the paper.
Insert the folded paper next to the stack
pressure sensors with the VIN and date visible
when taking the STUI photo.
VIN & DATE
If the sensor is labeled same as the “After
Improvement” image (no white label), then
submit STUI photo of the sensors and note, the
procedure is complete.
STUI
Using STUI, photograph the stack
pressure sensors with the current labels.
Include in the photos a piece of paper
containing the last 6 digits of the VIN and
the date of the repair. Ensure the photo
is in focus and captures the stack
pressure sensor labels and the note.
Upload the photo to STUI.
4.
If the sensors have a white label the same as
the “Before Improvement” image, then submit a
STUI photo of the sensors with note and
proceed to “Service Procedure” and replace
both sensors with the new parts
(35872-M5100QQH).
STUI
Using STUI, photograph the stack
pressure sensors with the white labels.
Include in the photos a piece of paper
containing the last 6 digits of the VIN and
the date of the repair. Ensure the photo
is in focus and captures the stack
pressure sensor labels and the note.
Upload the photo to STUI.
TSB #: 22-01-086H
Page 4 of 12
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HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Service Procedure
12-volt and High-Voltage Circuit Disconnection
1.
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 #: 22-01-086H
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2.
Disconnect the 12-volt battery negative (-)
connector.
!
3.
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
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 #: 22-01-086H
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4.
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Follow A-D below to remove the orange high
voltage safety plug.
Safety Plug Removal
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.
TSB #: 22-01-086H
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HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
6. Open the hood. Remove the junction box trim
and cover.
High Voltage Junction Box (HVJB) cover:
Assembly bolt torque:
`
lb-ft
kgf.m
N.m
•7.2 - 8.7
•1.0 - 1.2
Junction Box Trim
•9.8 - 11.8
HVJB Cover
7. 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.
!
•
8.
-
Measure
Voltage Here
+
DANGER
Electrocution hazard - The High
Voltage Junction Box (HVJB) may be
electrically energized up to 450 volts.
Reinstall the HVJB cover.
TSB #: 22-01-086H
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HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Stack Pressure Sensors Replacement Procedure
1. Use compressed air to blow off any dirt and
foreign material around the hydrogen pressure
sensors.
2. Remove the Blower Power Control Unit (BPCU)
connector (A).
A
3.
Remove connector (B) from hydrogen pressure
sensor #1 and connector (C) from hydrogen
pressure sensor #2.
C
B
4.
Loosen the bolts (D) of hydrogen pressure
sensor #1 and bolts (E) of hydrogen pressure
sensor #2 using the appropriate wrench or
socket.
D
E
Tightening Torque:
lb-ft
kgf.m
N.m
•5.8
•0.8
•7.8
TSB #: 22-01-086H
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5.
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Remove the hydrogen pressure sensor #1 (F)
and the hydrogen pressure sensor #2 (G).
G
F
6.
Visually inspect the foil membrane and O-ring of
the new hydrogen pressure sensor. If they are
undamaged, then install the sensor.
NOTICE
•
•
•
Damage to the sensor may occur if
the metal foil membrane contacts
other objects. Do not touch or allow
sensor membrane to contact other
objects.
Use extreme care when handling and
installing the sensor. Keep protective
cap installed until the sensor is ready
to install.
Inspect the hydrogen pressure sensor
O-ring. If it is damaged, install another
undamaged sensor.
Foil Membrane
•
7.
Install hydrogen pressure sensor #2, then install
hydrogen pressure sensor #1.
TSB #: 22-01-086H
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8.
HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
Take a STUI photo zoomed in on the stack
pressure sensors labels with the note. The area
is dark. Use additional lighting for photo clarity.
Upload photo to STUI.
STUI
Using STUI, photograph the stack
pressure sensors with the revised labels.
Include in the photos a piece of paper
containing the last 6 digits of the VIN and
the date of the repair. Ensure the photo
is in focus and captures the stack
pressure sensor labels and the note.
Upload the photo to STUI.
9.
Reinstall the HVJB trim and any remaining parts
in reverse order of disassembly.
i Information
•
When installing the connectors, listen
for a clicking sound to confirm the
connector is properly seated.
.
TSB #: 22-01-086H
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HYDROGEN STACK PRESSURE SENSOR INSPECT AND REPLACE (CAMPAIGN T9C)
10. Using the GDSM, perform the following FCU
calibrations for the replaced hydrogen sensors.
• Offset resetting of the hydrogen pressure
sensor.
• Correction of the hydrogen pressure
sensor.
Refer to the shop manual for the complete
procedure.
FCU recalibration:
Fuel Cell System > Fuel Processing System >
Hydrogen Pressure Sensor1, Hydrogen Pressure
Sensor2 > Repair procedures > Offset resetting
of the hydrogen pressure sensor > Correction of
the hydrogen pressure sensor
11. With the vehicle in READY mode, check for
Hydrogen leaks at Hydrogen Pressure Sensor 1
and 2 using a combustible gas detector.
Refer to the shop manual for the leak check
procedure.
Hydrogen leak test:
Hydrogen Storage System > Repair procedures >
Hydrogen Gas Leak Test
If a leak(s) is detected, turn off the vehicle and
safely repair the leaks.
If no leaks are detected, then proceed to the
next step.
12. Using the Hyundai GDS Mobile scan tool, check
all systems for Diagnostic Trouble Codes
(DTCs). Record DTCs that are unrelated to this
TSB and clear all DTC’s.
13. Diagnose and repair any DTCs unrelated to this
procedure.
14. The service procedure is complete.
TSB #: 22-01-086H
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