High Pressure Fuel Pipe Inspection And Replacement (Recall 207) – 2021-2022 Hyundai Santa Fe & Sonata

July 9, 2021 NHTSA CAMPAIGN NUMBER: 21V524000

Fuel Leak at Pipe Connection

A fuel leak increases the risk of a fire.

 

NHTSA Campaign Number: 21V524

Manufacturer Hyundai Motor America

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 15,752

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2021-2022 Santa Fe and Sonata vehicles equipped with 2.5L turbocharged engines. Fuel may leak at the pipe connection between the high-pressure fuel pump and fuel rail.

 

Remedy

Dealers will inspect and tighten, or replace the fuel pipe as necessary, free of charge. Owner notification letters were mailed on September 3, 2021. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 207.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Hyundai has a Recall

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IMPORTANT

As required by federal law, dealer must not deliver new vehicle for sale or for lease to customers until all open recalls have been performed. Dealers should also perform all open recalls on used vehicles, demo, and rental vehicles prior to placing them into customer use 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 (VIS)” WEBDCS to identify open Campaigns.

 

Description: On certain 2021-2022MY Santa Fe (TMa) and Sonata (DN8a) vehicles equipped with 2.5T GDI engines, the fuel pipe connecting the high-pressure fuel pump to the fuel rail may have been installed with insufficient torque during assembly.  Additionally, certain fuel pipes could have been produced outside of Hyundai’s specification for concentricity.  A fuel pipe that has been installed with insufficient torque or improper concentricity could allow fuel to leak at its connections increasing the risk of an engine compartment fire. Follow the procedure outlined in this TSB to inspect, tighten and/or replace, the fuel pipe as needed.

 

Applicable Vehicles: 

Certain 2021-2022MY Santa Fe (TMa) vehicles equipped with 2.5T GDI engines. Certain 2021-2022MY Sonata (DN8a) vehicles equipped with 2.5T GDI engines.

 

Parts Information:

 

 

Special Service Tool Information:

 

NOTE: This is an essential tool that was previously shipped to all active dealers. Additional units can be ordered through Bosch at 1-866-539-4248.

 

Inspection Procedure:

1. Open the hood and remove the engine top cover (A).

 

2. Locate the high pressure fuel pipe and pipe insulator (as shown by the red arrow).

 

3. On the high-pressure fuel pipe insulator, locate the printed LOT number.

 

4. Review the LOT number inspection criteria below for the high pressure fuel pipe.

➢ If the LOT number is 210111, it is NG.

• Take a picture of the LOT number and replace the high-pressure fuel pipe with the Service Procedure on page 8.

 

➢ If the LOT number is not 210111, it is OK.

• Take a picture of the LOT number proceed to step 5 in the Inspection Procedure.

 

Using STUI, take clear picture(s) of the Lot Number.

 

Please include the VIN or copy of the RO with the VIN in the STUI picture of the fuel pipe.

 

NOTICE

For a guide on how to capture pictures and videos using STUI, refer to the Hyundai Tech Info website and select:
Diagnostic Tools > GDSM and STUI Tips > Tip #622 “Capturing Video and Photos for Techline and PA using the STUI Camera”

 

5. Remove the high-pressure fuel pump foam cover (B).

 

6. Remove the air intake hose (C) and the air cleaner assembly (D).

 

NOTICE 

Tightening Torque:

• Intake hose clamp:
  • 2.9 lb-ft (3.9 Nm)

 

• Air cleaner mounting bolt:
  • 6.5 lb-ft (8.8 Nm)

 

7. Using a torque wrench and SST 09314-3Q100, verify that the high-pressure fuel pump flange  nut (E) is torqued to specification.

 

NOTICE

Tightening Torque:

• 25 lb-ft (34 Nm)

 

8. Using a torque wrench and SST 09314-3Q100, verify that the high-pressure fuel rail flange  nut (F) is torqued to specification.

 

NOTICE

Tightening Torque:

• 25 lb-ft (34 Nm)

 

9. Reinstall the air intake hose (C) and the air cleaner assembly (D).

 

NOTICE  

Tightening Torque:

• Intake hose clamp:
  • 2.9 lb-ft (3.9 Nm)

 

• Air cleaner mounting bolt:
  • 6.5 lb-ft (8.8 Nm)

 

10. Turn the ignition switch ON and start the engine. Step on the accelerator pedal until engine reaches 5000 RPM.

Repeat 2-3 times, building fuel pressure in the  high pressure fuel pipe to expose leaks.

 

11. Turn the ignition switch OFF and disconnect the RCV hose (G) to begin air cleaner removal.

Removing the air cleaner is necessary to  properly inspect for leaks using the oil test  paper.

 

12. Disconnect the air intake hose (C).

If extra working room is needed, remove the air cleaner assembly (D).

 

NOTICE  

 Tightening Torque:

• Intake hose clamp:
  • 9 lb-ft (3.9 Nm)

• Air cleaner mounting bolt:
  • 5 lb-ft (8.8 Nm)

 

13. Inspect before and after the high pressure fuel pump flange for leakage using an oil test paper.

 

14. Inspect before and after the high pressure fuel rail flange for leakage. Use the other side of the oil test paper if necessary.

 

15. If no leak is found, reinstall parts in reverse order of disassembly. Removal and replacement are not necessary.

 

16. If fuel leak is found, replace high pressure fuel pipe with the following service procedure below.

 

NOTICE

After pipe inspection, if there is a sufficiently dry area on the previously used test oil paper, use it again for reinspection. Otherwise, use a new test oil paper strip.

 

Fuel Pipe Replacement Service Procedure:

1. Deplete the residual fuel pressure in the fuel lines following the procedure outlined in the Shop Manual section.

 

Refer to the shop manual section for complete service procedure:

Engine Control / Fuel System > Fuel Delivery System > Release Residual Pressure in Fuel Line

 

NOTICE

Be sure to wrap the connection joints with a shop towel to capture any dripping fuel.

 

2. Turn the ignition switch OFF and disconnect the battery (-) terminal.

 

NOTICE

Be sure to record the radio presets prior to battery disconnection.

 

3. If not already removed, disconnect the air intake hose (C).

If extra working room is needed, remove the air cleaner assembly (D).

 

NOTICE

Tightening Torque:

• Intake hose clamp:
  • 2.9 lb-ft (3.9 Nm)
• Air cleaner mounting bolt:
  • 6.5 lb-ft (8.8 Nm)

 

4. Remove the high pressure pipe bracket bolts (H) and fuel pump flange nut (E).

Remove the high pressure fuel rail flange nut (F) with SST 09314-3Q100.

 

NOTICE

Tightening Torque:

• High pressure pipe bracket bolts:
  • 7.95 lb-ft (10.8 Nm)
• High pressure pump flange nut:
  • 25 lb-ft (34 Nm)

 

5. Remove the high pressure fuel rail flange nut (F) with SST 09314-3Q100.

 

NOTICE

Tightening Torque:

• 25 lb-ft (34 Nm)

 

6. Remove the damaged high pressure fuel pipe.

7. Install the new pipe and reinstall the removed parts in reverse order of removal and reconnect the negative battery terminal.

 

NOTICE

Reprogram the radio presets from Service Procedure Step 2.

 

8. After installing the new high pressure fuel pipe, proceed to Inspection Procedure steps 10-16 to verify that the leak issue has been resolved.

 

NOTICE

After pipe inspection, if there is a sufficiently dry area on the previously used test oil paper, use it again for reinspection. Otherwise, use a new test oil paper strip.

 

9. The service procedure is now complete.

 

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RECALL 207 ATTACHMENT A

CHRONOLOGY OF EVENTS LEADING UP TO DEFECT DECISION

 

• March 2021

On March 29, 2021, HMMA detected a condition of fuel odor on a newly-assembled model year 2021 Hyundai Santa Fe vehicle during a routine end-of-line vehicle inspection.  HMMA immediately launched an investigation and confirmed vehicles with insufficient torque at the high-pressure pipe connections between the high-pressure fuel pump and the fuel rail.  HMMA notified HMA of their findings on March 31, 2021 and began reviewing production records to determine flow-out of vehicles potentially containing the suspected defect.

 

• April 2021

Based on HMMA’s investigation, HMA’s NASO performed an analysis of market data and found no incidents related to the suspect defect condition in the U.S. market.  HMMA concluded their review of production records and determined that two vehicles were delivered to Hyundai dealerships. NASO convened its North American Safety Decision Authority on April 26, 2021 and decided to notify the agency of a safety recall campaign to inspect and repair the two affected vehicles.

 

• June – July 2021

On June 16, 2021, Kia America, Inc. (“KUS”) received a report of fuel odor involving a Kia vehicle equipped with the same fuel pipe used in Hyundai vehicles affected by Recall 206.  KUS, along with HMMA, conducted a joint inspection of the incident vehicle and recovered the fuel pipe for further analysis.  The recovered fuel pipe was installed on an exemplar vehicle and confirmed to be leaking fuel despite being properly torqued.  Further examination confirmed that the pipe did not meet Hyundai/Kia’s specification for concentricity.  HMMA worked jointly with the fuel pipe supplier and identified a suspect production lot dated January 11, 2021 containing potentially defective fuel pipes caused by instability of the pipe diameter forming machine pin.

On July 1, 2021, HMMA informed NASO of its findings confirming certain Hyundai vehicles might contain potentially defective fuel pipes from the suspect production lot identified in the Kia investigation.  HMMA also informed NASO that, in addition to the issue of improper concentricity, there was a possibility that additional Hyundai vehicles other than the two (2) affected by Recall 206 also may have been installed with insufficient torque, prompting consideration for expanding the original affected vehicle population of Recall 206.  Based on this information, NASO quickly convened its North American Safety Decision Authority on July 1, 2021 and notified the agency of its intent to file a new safety recall expanding Recall 206 to address potential concentricity and low torque of the fuel pipe in the subject Hyundai vehicles.

As of the date of this filing, Hyundai is not aware of any confirmed crashes, injuries or fires attributable to the recall condition. No related incidents have occurred in the U.S.

 

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4 Affected Products

Vehicles

 

 

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6 Associated Documents

Defect Notice 573 Report

RCLRPT-21V524-4718.PDF 214.293KB

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CHRONOLOGY

RMISC-21V524-7850.pdf 132.906KB

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Recall Acknowledgement

RCAK-21V524-9714.pdf 645.174KB

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Remedy Instructions and TSB

RCRIT-21V524-6520.pdf 745.673KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V524-5590.pdf 181.148KB

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Recall Quarterly Report #2, 2021-4

RCLQRT-21V524-1054.PDF 211.241KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V524&docType=RCL

 

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