23-01-015H-1

GROUP
NUMBER
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
23-01-015H-1
MODEL(S)
July 2023
NEXO (FE)
STACK COOLANT PUMP REPLACEMENT
(SERVICE CAMPAIGN T8W)
This TSB supersedes 23-01-015H by expanding the affected VIN range to include 2021MY
vehicles.
 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 via WEBDCS to identify open campaigns.
Description: In certain 2019-2021MY Nexo (FE) vehicles, the stack coolant pump may become
nonoperational. This is accompanied by multiple levels of warning to the driver including MIL (various
DTCs related to coolant stack pump), warning sounds, large messaging in the instrument cluster and
potentially entering EV mode with reduced vehicle speed. This bulletin provides a procedure to replace
the stack coolant pump with a revised part.
Applicable Vehicles (Certain): 2019-2021MY Nexo (FE) vehicles produced 8/10/2018 – 2/1/2021.
NOTICE
•
•
The TSB repair procedure MUST be performed at an authorized Hyundai NEXO fuel cell
vehicle dealer and by a Hyundai Service 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:
STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
Parts Information:
Part Name
Part Number
Stack Coolant Pump
25816-M5000QQH
Stack Coolant*
00232-19099 (2L)
Figure
Qty.
1
N/A
10L (5EA)
*The stack coolant part number for this campaign is a green color and compatible with the existing
blue color stack coolant.
Warranty Information:
Model
Op. Code
Operation
Op.
Time
Causal Part
Nature
Code
Cause
Code
Nexo (FE)
20D025R0
Stack Coolant Pump
Replacement
1.8
M/H
25816M5000QQH
I11
ZZ1
NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: If a part that is not covered by this campaign is found in need of replacement while
performing this service campaign and the affected part is still under warranty, submit a separate 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.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and Repair
validation photos as outlined in the Digital Documentation Policy.
NOTE 4: 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 not returned.
TSB #: 23-01-015H-1
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
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 #: 23-01-015H-1
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2.
STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
Disconnect the 12-volt battery negative (–)
connector.
!
3.
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 #: 23-01-015H-1
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4.
STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
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.
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
6. Open the hood. Remove the junction box trim
and cover.
High Voltage Junction Box (HVJB) cover:
Assembly bolt torque:
lb-ft
7.9
lb-in
95
Junction Box Trim
N.m
10.8
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.
!
–
Measure
Voltage Here
+
DANGER
Electrocution hazard - The High Voltage
Junction Box (HVJB) may be electrically
energized up to 450 volts.
8.
Reinstall the HVJB cover.
TSB #: 23-01-015H-1
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SUBJECT:
STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
Stack Coolant Pump Replacement
1. Remove the fuel cell stack room under cover (A).
Refer to Shop Manual:
•
A
Fuel Cell System > Fuel Cell Stack >
Fuel Cell Stack Room Under Cover >
Repair procedures
2. Drain the stack coolant.
Refer to Shop Manual:
•
Fuel Cell System > Thermal
Management System > Stack Coolant >
Repair procedures
3. Remove the air cleaner assembly.
Refer to Shop Manual:
•
Fuel Cell System > Air Processing
System > Air Cleaner > Repair
procedures
4. Remove the Stack Trim Cover (B).
Refer to Shop Manual:
•
B
Fuel Cell System > Fuel Cell Stack >
Fuel Cell Stack Cover > Repair
procedures
TSB #: 23-01-015H-1
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
5. Remove the stack coolant ion filter as an
assembly (C). DO NOT remove filters from
canister.
To prevent loss of coolant from filter canister,
insert a tapered plug into the upper hose fitting
on the filter canister, then remove the lower hose
from filter canister and insert a tapered plug into
lower hose fitting on the filter canister.
C
Refer to Shop Manual:
•
Fuel Cell System > Thermal
Management System > Stack Coolant
Ion Filter > Repair procedures
6. Remove the stack coolant reservoir (D) and do
not allow coolant to drain out of reservoir.
Refer to Shop Manual:
•
Fuel Cell System > Thermal
Management System > Stack Coolant
Reservoir Tank > Repair procedures
TSB #: 23-01-015H-1
D
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
7. Remove the stack coolant pump outlet hose (E).
E
Refer to Shop Manual:
•
Fuel Cell System > Thermal
Management System > Stack Coolant
Pump > Repair procedures
8. Disconnect the stack coolant pump wiring
connector (F) and wiring clip (G).
F
G
9. Disconnect the stack coolant pump inlet hose
clamp (H).
TSB #: 23-01-015H-1
H
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
10. Disconnect the stack coolant pump high voltage
cable connector (I).
I
(1) Remove the connector locking pin.
(2) Press on the 1st holding point.
(3) Insert a screwdriver into the 2nd holding point
and remove the high voltage connector by
2nd Holding
Point
pulling on the connector.
1st Holding
Point
11. Remove the stack coolant pump (J).
Tightening Torque:
lb-ft
16
N.m
22
J
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
12. Use shop compressed air to blow off any coolant
that may have dripped on the junction connector
when removing the stack coolant pump.
Stack Coolant Pump Disassembly and Replacement
13. Remove the stack coolant pump hose (K).
K
Remove the inlet and outlet hose (L).
i Information
Do not discard the stack coolant pump
hose. The pump hose will be installed onto
the replacement stack coolant pump.
L
14. Remove the ground wire (M) from the bracket.
M
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
15. Remove the pump bracket (N).
i Information
Do not discard the pump bracket. The
pump bracket will be installed onto the
replacement stack coolant pump.
N
16. Remove the rubber bushing (O).
O
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
17. Attach the rubber bushing to the new stack
coolant pump.
The rubber bushing and stack coolant pump
housing are indexed with a land and groove.
Align the groove in the rubber bushing with the
land on the stack coolant pump housing.
18. Attach the pump bracket and hose from the
original stack coolant pump to the new stack
coolant pump.
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
19. Before installing the replacement stack coolant
pump to the vehicle, use STUI to photograph the
labels on the replacement stack coolant pump
and submit photo through STUI.
STUI
Using STUI, photograph the stack
coolant pump labels. Include in the
photo a piece of paper containing the
last 6 digits of the VIN and date of
repair. Ensure the photo is in focus and
clearly captures the stack coolant
pump labels, especially the part
number, and note.
Upload the photo to STUI.
20. Install the replacement stack coolant pump to the
vehicle.
STUI
Using STUI, photograph the stack
coolant pump installed in the vehicle.
Include in the photo a piece of paper
containing the last 6 digits of the VIN
and date of repair. Ensure the photo is
in focus and captures the stack coolant
pump and note.
Upload the photo to STUI.
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
21. Reinstall all removed parts in reverse order of
removal.
i Information
•
•
Stack coolant 00232-19099 is green
and it is compatible with the existing
blue coolant that was previously in the
stack cooling system.
Coolant in the stack cooling system
will no longer appear blue after green
stack coolant is added.
22. Perform air bleeding of stack cooling system.
Refer to Shop Manual:
•
Fuel Cell System > Thermal
Management System > Stack Coolant >
Repair procedures
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STACK COOLANT PUMP REPLACEMENT (SERVICE CAMPAIGN T8W)
23. To assist with bleeding air from the cooling
system; during the air bleed process repeatedly
squeeze the stack coolant hoses by hand at the
coolant pump (P) and at the upper radiator hose
(Q).
P
Q
24. Check and clear any DTC that may have set
during the pump replacement procedure.
25. The service procedure is complete.
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