Recall 225 – Hydrogen Gas Detection Sensors May Fail – 2019-2021 Hyundai Nexo

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April 14, 2022 NHTSA CAMPAIGN NUMBER: 22V258000

Hydrogen Gas Detection Sensors May Fail

A hydrogen gas leak can increase the risk of a fire while parked or driving.

 

NHTSA Campaign Number: 22V258

Manufacturer Hyundai Motor America

Components FUEL SYSTEM, OTHER, ELECTRICAL SYSTEM

Potential Number of Units Affected 922

 

Summary

Hyundai Motor America (Hyundai) is recalling certain 2019-2021 Nexo vehicles. The hydrogen gas detection sensors may fail to detect leaks in the hydrogen gas delivery system.

 

Remedy

Owners are advised to park their vehicles outside and away from structures until the recall remedy is completed. Dealers will replace the hydrogen gas detection sensors, free of charge. Owner notification letters were mailed August 12, 2022. Owners may contact Hyundai customer service at 1-855-371-9460. Hyundai’s number for this recall is 225.

 

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

 


Description of Campaign: 

Certain 2019-2021MY NEXO (FE) vehicles may exhibit degradation in performance of the Hydrogen leak detection sensor caused by contamination of the sensor during manufacturing. The TSB 22-01-062H outlines the procedure to replace the Hydrogen Leak Detection Sensor located at the Fuel Processing System (FPS), the Fuel Stack Housing, and the Hydrogen Storage Tanks.

 

Affected Vehicles:

  • Certain 2019-2021MY Hyundai NEXO vehicles produced from 08/10/2018 – 06/28/2021 by Hyundai Motor Company (“HMC”) for sale in the U.S.
  • To check vehicle specific recall applicability, access the “Vehicle Information” screen (VIS) via WebDCS. Ø As of this remedy launch, there are no new vehicles currently in dealer stock.

 

The Fix: 

Remove and replace all three (3) of the Hydrogen Leak Detection Sensors.

  • Estimated Repair Time : 7 M/H

 

Recommended Alternative Transportation: It is recommended that Service Rental Cars (SRCs) be made available and provided for customers during the repair.

 

Customer Notification

NHTSA has posted this recall. Owners are expected to be notified in August 2022 of a remedy available.

 

Customer FAQ: 

Q1: What is the issue?

A1: The hydrogen gas detection sensors in the subject vehicles may degrade over time, resulting in an inability to detect leaks in the hydrogen gas delivery system and illuminate the associated warning light.

 

Q2: What is the safety concern?

A2: A failure to alert the operator of a hydrogen gas leak could increase the risk of a vehicle fire while parked or driving.

 

Q3: Can owners continue driving these vehicles? Should they park them indoors or outdoors?

A3: Owners can continue driving these vehicles. However, Hyundai strongly recommends parking their vehicles outside and away from structures until the recall remedy is completed.

 

Q4: Has there been any accidents or injuries?

A4: If a customer does not feel safe driving in his/her vehicle, he/she should bring his/her vehicle to the dealership and be put in a service rental vehicle until the remedy is completed.

 

Q5: Has there been any accidents or injuries?

A5: As of the date of filing to NHTSA (04/14/2022), there were no related fires or injuries in the U.S. or Canada.

 

Q6: What will be done during this recall service at the dealer?

A6: Owners can continue driving these vehicles. However, Hyundai strongly recommends parking their vehicles outside and away from structures until the recall remedy is completed. All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to have the hydrogen gas detection sensors replaced.

This remedy will be offered at no cost for all affected customers.

 

Q7: What if the owner incurred out-of-pocket expenses for obtaining a remedy for the recall condition?

A7: Hyundai will provide owners of affected vehicles reimbursement for out-of-pocket expenses incurred to obtain a remedy for the recall condition in accordance with the reimbursement plan submitted to NHTSA on February 24, 2022.

 


22-01-062H
July 2022

HYDROGEN LEAK DETECTION SENSOR REPLACEMENT (RECALL 225)

 

IMPORTANT

*** Retail Vehicles ***

Vehicle repairs related to safety recalls are critically important and must be performed properly in accordance with TSB procedures. Review this bulletin in its entirety prior to beginning any repair work.

As required by federal law, dealer must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers must 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.

Description: Certain 2019-2021MY NEXO (FE) vehicles may exhibit degradation in performance of the Hydrogen leak detection sensor caused by contamination of the sensor during manufacturing. This bulletin outlines the procedure to replace the Hydrogen Leak Detection Sensor located at the Fuel Processing System (FPS), the Fuel Stack Housing, and the Hydrogen Storage Tanks.

Applicable Vehicles: Certain 2019-2021MY NEXO (FE) vehicles produced from 08/10/18 – 06/28/21

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Chronology :

January 2022
On January 17, 2022, HMC received information regarding a manufacturing change implemented by the supplier to increase the platinum particle size on the catalyst component(s) of the hydrogen gas detection sensors equipped in certain 2019-2021 model year Nexo vehicles in South Korea. HMC notified HMA’s NASO of the changepoint on January 24, 2022, prompting a new joint investigation into the condition and its potential effect on vehicles in the field. NASO began a review of field information for potential incidents in the U.S. related to the reported condition.

February 2022
NASO completed its review of U.S. field information and found no incidents had occurred in the U.S. Per a request made by HMC’s investigative team, NASO recovered two (2) functional sensors from in-use fleet vehicles and sent them to HMC for replication testing and root cause analysis.

March 2022
In early to mid-March, NASO continued to actively monitor field information for potential incidents. No incidents were found during this time. Two (2) additional functioning sensors from fleet vehicles were recovered and sent to HMC to aid in testing on March 24, 2022.

On March 30, 2022, HMC shared its findings with NASO. According to HMC, laboratory testing confirmed that the smaller platinum particle size on the sensor catalysts allowed for silicon to accumulate on the catalyst surface and create a film that lowered the sensor’s ability to detect hydrogen gas concentration. HMC informed NASO and advised of potential vehicles affected in the U.S. and Canada.

April 2022
Based on the information received from HMC, on April 7, 2022, NASO convened its North America Safety Decision Authority and decided to conduct a new recall of affected Hyundai Nexo vehicles in the U.S. to address the defect condition involving the hydrogen gas detection sensor(s).

As of the date of this filing, there are no confirmed fires, injuries, or related incidents in the U.S.

 


3 Affected Products

Vehicle

MAKE MODEL YEAR
HYUNDAI NEXO 2019-2021

 


12 Associated Documents

Defect Notice 573 Report

RCLRPT-22V258-4722.PDF 214.573KB

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Recall Acknowledgement

RCAK-22V258-6074.pdf 645.197KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V258-6825.pdf 236.1KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V258-5446.pdf 327.294KB

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Remedy Instructions and TSB

RCRIT-22V258-4732.pdf 814.679KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V258-1037.pdf 495.368KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V258-6121.pdf 226.407KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V258-5932.PDF 211.13KB

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ISSUED Renotification Notice

RCRN-22V258-4237.pdf 117.246KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V258-8890.PDF 211.237KB

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ISSUED Renotification Notice

RCRN-22V258-1797.pdf 193.798KB

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ISSUED Renotification Notice

RCRN-22V258-1331.pdf 194.358KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V258&docType=RCL

 


 

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