Recall 240 Fuel Tank – 2022 Hyundai Santa Fe Plug-In Hybrid

SEOCONTENT-START

(8;>HYUnDRI
Web version
##SMFMT_PROPERCASE[\customer_first_name]##, A Safety Recall has been issued on your ##model_year##
##SMFMT_PROPERCASE[\model_short_name]##’s Fuel Tank. Recall ##campaign_number## Remedy is Available
This notice applies to your vehicle, VIN: ##VIN## What will Hyundai do?
Your Hyundai dealer will inspect and replace the fuel tank, if necessary.
This procedure will be performed at
NO CHARGE. To ensure your safety and the quality of your vehicle, please schedule an appointment with a Hyundai dealer as soon as possible to complete the remedy procedure. Schedule appointment
What is the problem? The fuel tanks in the subject vehicles may have been improperly manufactured resulting in a fuel leak at the seam between the tank halves. A fuel leak in the presence of an ignition source can increase the risk of a fire. Our records indicate that your vehicle is affected. Additional Information For more information about this critical recall including affected vehicles or frequently asked questions, you may view HY.undai’s official camP-aign Rag.§. or visit the NHTSA website. If you require further assistance, including info on reimbursement or updating ownership, please visit the HY.undai Consumer Assistance Center or by calling the Hyundai Motor America Virtual Assistant at 1-855-371-9460. To better assist you during your call please have the last 8 characters of your VIN ready to enter when prompted. Last 8 Characters: ##last 8 vin## (8)HYUnDAI NHTSA.GOV HYUNDAIUSA.COM PRIVACY OGOS
You are receiving this notice because our records indicate that you own or lease the vehicle identified by the VIN on this notice. This is an outbound email only. Please do not reply to this email.
This message was transmitted by Hyundai Motor America. Hyundai is a registered trademark of Hyundai Motor Company. Hyundai model
names are registered trademarks of Hyundai Motor America.
All rights reserved. ©2023 Hyundai Motor America.

**************************************************************************************************************

Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair Technical Service Bulletin
GROUP
RECALL
DATE MARCH 2023
NUMBER
23-01-020H
MODEL
SANTA FE
Plug-In Hybrid (TM PHEV) SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240)
Description: On certain 2022MY Santa Fe Plug-In Hybrid (TM PHEV) vehicles, the fuel tank may be built out of specification which could lead to a fuel leak. Follow the service procedure to inspect the
fuel tank LOT code and replace the fuel tank if necessary.
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, dealers 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.
Access the “Vehicle Information” screen* via WEBDCS to identify open Recalls.
🞳
ANT
This TSB includes STUI pictures as a requirement. Where indicated, please include the 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 the 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.
STUI SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) IMPORTANT 1st STEP*: When looking up the VIN in the “Vehicle Information” screen, make sure to go to the “Campaign Not Performed” section, and view the “Campaign Description” field.
• If the op code listed is “21D181R2”, then skip directly to the procedure for fuel tank replacement on page 5. • If there is no op code listed, then proceed to performing the LOT Code inspection of the fuel tank. Applicable Vehicles:
MODEL PRODUCTION DATE RANGE Certain 2022 Santa Fe Plug-In Hybrid (TM PHEV) April 11, 2022 – July 21, 2022 Parts Information:
PART NAME PART NUMBER NOTES
Replace fuel tank only if under one of these (2) criterias: FUEL TANK ASSEMBLY
(w/ Service Kit*) BOLT
(Propeller Shaft) 31150-P4800QQH 11435-10256K • If WEBDCS shows “21D181R2 – Fuel Tank Replacement”
• If fuel tank has affected LOT Code.
NOTE: Includes one (1) new O-ring for the fuel pump module. Order six (6) new flange bolts (3 Front, 3 Rear) to be used during reinstallation of the propeller shaft whenever the fuel tank is being replaced. Warranty Information:
MODEL OP CODE OPERATION OP
TIME CAUSAL P/N NATURE
CODE CAUSE CODE Santa Fe Plug-In Hybrid
(TM PHEV) 21D181R0 21D181R1 21D181R2 FUEL TANK LOT CODE INSPECTION ONLY FUEL TANK LOT CODE INSPECTION AND REPLACEMENT
FUEL TANK REPLACEMENT ONLY (WEBDCS SHOWS VIN HAS AFFECTED LOT CODE) 0.3M/H 2.5M/H 2.3M/H 31150-P4800QQH B25 ZZ4 NOTE 1: Submit claim on Campaign Claim Entry Screen
NOTE 2: If a part that is not covered by this recall is in need of replacement while performing this recall, and the affected part is still under warranty, please 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: Op times include taking STUI photo(s) and uploading. The STUI photo(s) must include the LOT Code on the fuel tank of the inspected tank (not required for op code 21D181R2) and newly replaced tank (if replacement was necessary) along with a piece of paper displaying the last 6 digits of the VIN and date of the repair. If not included, claim will be subject to debit.
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 parts requested are not returned. TSB #: 23-01-020H Page 2 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) Service Process Overview: (Refer to the QR link for additional video information 🡺)
Service Procedure: 1. Look up the VIN in the “Vehicle Information” screen via WEBDCS and go to the “Campaign Not Performed” section to view the “Campaign Description” field for Recall 240.
⮚ If the op code listed is “21D181R2”, then skip directly to Fuel Tank Replacement on page 5. ⮚ If there is no op code listed, then follow Fuel Tank LOT Code Inspection on next page. TSB #: 23-01-020H Page 3 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) *** Fuel Tank LOT Code Inspection ***
2. Lift vehicle on a hoist.
⮚ Refer to Shop Manual: General Information > Lift and Support Points 3. Locate the inspection point (A) after lifting the A
vehicle. 4. Remove the heat shield fasteners (B) of the fuel tank. B C 5. Position the heat shield slightly away to record the Year/Month/Day LOT Code (C) imprinted on the fuel tank and check if it is in the affected LOT range. STUI LOT Code Inspection Point Using STUI in the GDS, take a picture of the EXISTING Fuel Tank LOT Code with last 6-digits of VIN and date of repair on a piece of paper.
Ensure the picture is in focus and VIN with
date of repair are legible.
Upload the photo in STUI. NOTE: See next page for detailed information regarding the LOT Code reading method. TSB #: 23-01-020H Page 4 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) NOTE: Read the printed LOT Code with the numbers facing correctly (right side up, not upside down), starting from LEFT (Year), MIDDLE (Month), RIGHT (Day). The LOT Code indication arrows follow clockwise direction to indicate the number in 1 unit increments from the appropriate Reference Point.
� Year [Reference Points 18, 21, 24, 27]
� Month [Reference Points 3, 6, 9, 12]
� Day [Reference Points 1, 5, 10, 15, 20, 25, 30] EX) 22(YEAR) EX) 4(MONTH) EX) 7(DAY) The following are affected LOT Codes that require fuel tank replacement:
▪ 22 4 7 (Year 22, Month 4, Day 7)
▪ 22 4 8 (Year 22, Month 4, Day 8)
▪ 22 4 9 (Year 22, Month 4, Day 9) ⮚ If the inspected fuel tank LOT Code matches any of the affected LOT Codes listed above, then follow the remaining service procedure to perform Fuel Tank Replacement.
⮚ If the inspected fuel tank LOT Code are not part of the affected LOT Codes, then the service procedure is complete. Do not replace the fuel tank. *** Fuel Tank Replacement *** D
6. Release the residual pressure in fuel line.
⮚ Refer to Shop Manual: Fuel Delivery System
> Release Residual Pressure in Fuel Line 7. Turn the ignition switch OFF and disconnect the battery (-) terminal.
NOTE: Be sure to record radio presets before battery disconnection. 8. Remove the (LH) rear seat.
⮚ Refer to Shop Manual: Body > Rear Seat Assembly 9. Remove the fuel pump service cover (D). NOTE: When removing the fuel pump service cover, remove the 4 clips by rotating them clockwise. TSB #: 23-01-020H Page 5 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) 10. 11. 12. 13. Disconnect the Fuel Pump Control Module (FPCM) connector (E).
E
Disconnect the fuel tank pressure sensor F
connector (F). Disconnect the Fuel Pressure Sensor (FPS) connector (G). Disconnect the fuel feed tube quick connector (H). G H
I 14. Lift the vehicle. 15. Remove the floor under cover (I).
Tightening Torque:
• Fasteners 🡺 9.85 Nm (87 lb-in) 16. Remove the catalytic converter & center muffler assembly.
⮚ Refer to Shop Manual: Engine Mechanical System > Muffler 17. Remove the propeller shaft assembly.
⮚ Refer to Shop Manual: Driveshaft and Axle > Propeller Shaft Assembly NOTES:
⮚ Prior to removing the propeller shaft, be sure to note the “1” and “2” indexing marks at the front and rear flanges. It must be reinstalled
at the same indexed positions. 2 1
⮚ If necessary, use a paint pen to create new index marks at each end of the propeller shaft and mating flanges for reference. TSB #: 23-01-020H Page 6 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) ⮚ Remove the entire multiple propeller shaft pieces completely as one unit. To prevent possible damage or imbalance, do not try to separate the propeller shaft pieces.
⮚ Do not reuse the propeller shaft flange bolts. Use the 6 newly supplied bolts with 14mm sized hex heads (P/N 11435-10256K) during propeller shaft reinstallation.
⮚ When the propeller shaft is being reinstalled after installing the new fuel tank, be sure to realign and match the “1” and “2” indexing marks (or newly drawn lines) at the flanges. Tightening Torque:
• 6 Flange Bolts (New) 🡺 61 Nm (45 lb.-ft)
• 4 Carrier Bolts (Reuse) 🡺 61 Nm (45 lb.-ft) 18. 19. 20. 21. 22. Disconnect the purge tube quick-connector (J). Disconnect the Fuel Tank Isolation Valve (FTIV) extension wiring connector (K). Disconnect the recirculation tube quick- J
connector (L). Disconnect the air vent tube quick-connector (M). Separate the fuel filler neck hose (N). L M
K N TSB #: 23-01-020H Page 7 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) 23. Support the fuel tank with a jack or suitable component lifting platform (O). NOTE: Insert the rubber block (or equivalent) between the fuel tank and jack/platform to prevent damage to the fuel tank. O 24. Remove the fuel tank bands (P) and then remove the fuel tank (Q).
Tightening Torque:
• Fuel Tank Band Fasteners 🡺 5 Nm (44 lb-in) P NOTE: Do not over-torque. Q 25. Remove the fuel pump module and remove the fuel inside the fuel tank (to transfer over to the new fuel tank using a suitable siphoning pump). NOTE: The newly supplied O-ring of the fuel pump module top plate must be installed during reinstallation. TSB #: 23-01-020H Page 8 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) 26. Loosen the heat shield fixing bolts. 27. Loosen the 2 fasteners of the Fuel Tank Isolation Valve (FTIV). 28. Disconnect the tube and wiring from the 5 fixed locations. 29. Remove the quick connector of the Fuel Tank Isolation Valve (FTIV). TSB #: 23-01-020H Page 9 of 11 SUBJECT: FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240) 30. Loosen the 2 charcoal canister mounting fasteners and raise the canister upwards to dislodge it from the fuel tank. Tightening Torque:
• Mounting Fasteners 🡺 4 Nm (35 lb-in) NOTE: Do not over-torque. 31. Reinstall the removed parts (fuel pump module, charcoal canister, FTIV, and bottom heat shield) onto the newly supplied fuel tank. NOTE: Fuel Tank Assembly (P/N 31150- P4800QQH) includes the Service Kit with the following contents.
• 6x Fuel Tank Rubber Pads (R)
• 1x Clip Pad Assembly (S)
• 1x Clip (T)
• 3x Clips (U)
• 1x Fuel Pump O-Ring (V)
� Be sure to install all items of the Service Kit. S R
U R U
R V T Fuel Tank R
Assembly R R
⮚ U TSB #: 23-01-020H Page 10 of 11 FUEL TANK LOT CODE INSPECTION AND REPLACEMENT (RECALL 240)
TSB #: 23-01-020H Page 11 of
SUBJECT:
32.
33. 34.
35.
Record the LOT Code of the new fuel tank.
Reinstall all other components in reverse order of removal. Reconnect the battery (-) terminal. NOTE: Reprogram the radio presets recorded from Service Procedure Step 7. Start the engine and confirm all function is normal with no warning lights ON.
Using STUI in the GDS, take a picture of the NEW Fuel Tank LOT Code with last 6- digits of VIN and date of repair on a piece of paper.
Ensure the picture is in focus and VIN with date of repair are legible.
Upload the photo in STUI.

**************************************************************************************************************

Dear
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Hyundai has decided that a defect, which relates to motor vehicle safety, exists in certain 2022 Model Year Santa Fe Plug-In Hybrid vehicles. To ensure the safety of its vehicles for Hyundai customers, we are initiating Safety Recall 240 to repair a condition involving the fuel tank in these vehicles in the U.S. Our records indicate that your vehicle is affected by this recall.
What is the problem?
The fuel tanks in the subject vehicles may have been improperly manufactured resulting in a fuel leak at the seam between the tank halves. A fuel leak in the presence of an ignition source can increase the risk of a fire.
What will Hyundai do?
Your Hyundai dealer will inspect and replace the fuel tank, if necessary. This procedure will be performed at NO CHARGE to you.
What should you do?
Please contact your nearest Hyundai dealer to schedule this procedure.
The actual time required to perform this procedure on your vehicle will take less than one hour, however, your vehicle may be needed longer. To find your Hyundai dealer in order to schedule an appointment:
• Visit www.hyundaiusa.com/dealer-locator and enter your zip code to locate a nearby Hyundai dealer.
• Scan QR code shown at right with your smartphone camera to access the online Hyundai dealer locator.
• Contact Hyundai Motor America at 1-855-371-9460 and select Option 3 for the Dealer Locator.
– When calling, please have available the last 8 characters of your VIN (written in bold characters at the top of this notice).
Additional information
If you believe that the dealer and/or Hyundai has failed or is unable to remedy the defect without charge, or within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll-free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov.
Thank you for your attention to this important safety matter. We apologize for any inconvenience this may have caused you.
Hyundai Motor America
Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937
IMPORTANT SAFETY RECALL
Fuel Tank
Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”
NHTSA Recall Number: 23V-028
Hyundai Recall Number: 240
This is an important Safety Recall.
• Failure to complete this recall repair could lead to a potential fuel leak, which could increase the risk of a fire.
• The recall procedure will be performed on your vehicle at NO CHARGE to you.
• Hyundai recommends contacting your preferred dealer and scheduling an appointment in advance to avoid any inconvenience. To locate your nearest Hyundai dealer and schedule your appointment please visit:
www.HyundaiUSA.com/campaign240
Scan to locate Hyundai dealer
This notice applies to your 2022 Hyundai Santa Fe Plug-In Hybrid vehicle, VIN: XXXXXXXXXXXXXXXXX
Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937
NHTSA Recall Number: 23V-028
Hyundai Recall Number: 240
If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Do you want to learn more about this Safety Recall and schedule your appointment?
To learn more about this safety recall, including the remedy repair, and other commonly asked questions, and how best to schedule your appointment, please visit:
www.hyundaiusa.com/campaign240
Have you previously paid for this repair?
If you have previously paid for a repair that addresses the issue described in this letter, you may be eligible for a reimbursement. Use the link shown at right to submit your reimbursement request, or to obtain additional information, call 1-855-371-9460.
https://owners.hyundaiusa.com/content/myhyundai/us/en/contact-us/campaign.html
No longer own this vehicle?
You received this notification because U.S. federal regulations require automotive manufacturers to notify last known owners of recalled vehicles based on current owner records. Our records are based primarily on state registration and title data, which indicate that you are the current owner.
If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner.
IMPORTANT SAFETY RECALL
To Schedule Appointment:
To Call Hyundai:
Reimbursement Request:
QR codes for easy access
You can easily connect with
Hyundai Motor America via webpage or phone call by pointing your smartphone camera (or QR code reader app) at the QR code(s) below. Then select the link that will be displayed on your phone.

**************************************************************************************************************

Recall 240: Fuel Tank Lot Code Inspect & Replace – Dealer Best Practice
March 06, 2023
Updates to this Document Date
• Recall 240: Fuel Tank Lot Code Inspection and Replacement (TSB 23-01-020H) 03/06/2023
Recall Description:
On certain 2022MY Santa Fe Plug-In Hybrid (TM PHEV) vehicles, the fuel tank may have been built out of specification which could lead to a fuel leak. A fuel leak in the presence of an ignition source can increase the risk of a fire. TSB 23-01-020H (or latest version) provides the service procedure to inspect the fuel tank LOT code and replace the fuel tank if necessary. Affected Vehicles:
• Certain 2022MY Hyundai Santa Fe Plug-In Hybrid (TM PHEV) vehicles produced from 04/11/2022 – 07/21/2022 Remedy Information:
• Inspect the fuel tank lot code and replace the fuel tank if necessary.
o When looking up the VIN in the “Vehicle Information” screen, check if the op code 21D181R2 is displayed.
o If the op code listed is “21D181R2”, then skip directly to the procedure for fuel tank replacement on the TSB. • If there is no op code listed, then proceed to first performing the LOT Code inspection of the fuel tank.
• Recommended Training Technician Level: Expert (or above) Recommended Alternative Transportation:
It is recommended that Service Rental Cars (SRCs) are made available for customers when fuel tank replacement is necessary. Warranty Information:
This recall campaign pays 0.3 M/H for a fuel tank inspection, 2.3 M/H for direct replacement (if op code 21D181R2 appears on the “Vehicle Information” screen via WEBDCS) & 2.5 M/H for fuel tank inspection & replacement.
• Op times include taking STUI pictures where necessary and uploading. The STUI photos must include the inspection result of the EPCU and new EPCU installed (if necessary, based on inspection) with a piece of paper displaying the last 6 digits of the VIN and date of the repair. If not included, claim will be subject to debit.
As required by federal law, dealers must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers must 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.
To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS. Acceptable STUI Photo of the Lot No. on Fuel Tank (zoom in to capture clearest picture) Please refer to TSB 23-01-020H (or latest version) for additional details. Parts Information:
• Please refer to TSB 23-01-020H (or latest version) for the latest parts information.
• Please consider the following:
o Fuel Tank (31150-P4800QQH): On CSP (Critical Parts Supply). Dealer will require a valid recall 240 VIN to order the part.
o BOLT – Propeller Shaft (11435-10256K): Order 6 only when fuel tank replacement is required. Customer Mailing:
• Owners of the subject vehicles are expected to be notified via First Class mail starting in late March 2023 of a remedy available for their vehicle. Customer Talk Tracks
Sample (customer already at dealership): “During your visit we checked to see if your vehicle has any open recalls. We found that Recall 240 for the fuel tank is open on your vehicle. We are going to inspect the fuel tank to determine if it was built out of specification or not. If the inspection does not pass, we will replace the fuel tank for you at no cost. The inspection and replacement of the fuel tank, if necessary, is important as a leak from the fuel tank could increase the risk of a fire in the presence of an ignition source.” This procedure will take a few hours so the dealership will provide you with a Service Rental Car (SRC) to offset the inconvenience of being without your vehicle. Sample (customer calling in): “During your call-in, we checked to see if your vehicle has any open recalls. We found that Recall 240 for the fuel tank inspection & replacement is open on your vehicle. We’d like to schedule an appointment with you to bring your vehicle in so we can complete this safety recall. We would inspect the fuel tank to determine if it was built out of specification or not and may have a leak. If the inspection does not pass, we will replace the fuel tank at no cost to you. The inspection and replacement of the fuel tank, if necessary, is important as a leak from the fuel tank could increase the risk of a fire in the presence of an ignition source. If this were to occur, you might detect a fuel smell and/or visible fuel leak. The fuel leak in the presence of an ignition source can increase the risk of a fire. If you experience any of the aforementioned symptoms of the recall prior to your arrival at the dealership, please have your vehicle towed to the nearest Hyundai dealership and do not attempt to drive the vehicle until a remedy has been applied.” Best Practice Checklist:
Reservation: After looking up the VIN in the “Vehicle Information” screen, is operation code 21D181R2 listed in the “Campaign Description” field under the “Campaign Not Performed” section?
□ Yes- Order the appropriate components identified in TSB 23-01-020H (or latest version).
□ No- Recall 240 still applies. Please schedule an appointment to have the fuel tank lot code inspected. Readiness: Were the appropriate parts ordered as per TSB 23-01-020H (or latest version) if replacement of the fuel tank was needed?
□ Yes – Provide customer with ETA and schedule a timing to have the replacement performed (if inspection does not pass OR operation code 21D181R2 shows up on the “Vehicle Information” screen).
□ No – Contact parts and order appropriate components. Reception: Did you get permission from the customer to perform the eMPI and review all declined services and additional recommended maintenance?
□ Yes
□ No Reception: Did you explain to the customer the expected repair time and an expectation for a status update?
□ Yes
□ No Reception: Did you offer the customer Alternative Transportation?
□ Yes
□ No Repair: Did you review the results of the eMPI with the customer and provide the customer with estimates for any recommendations and also an adjusted promise time based on any additional services?
□ Yes
□ No Repair: Is the Technician a Hyundai Expert Technician (or above)?
□ Yes
□ No Repair: Was a STUI picture(s) taken of the EXISTING fuel tank lot code (as necessary) and NEW fuel tank lot code (as necessary) with the last 6 digits of the VIN and date of repair per TSB 23-01-020H (or latest version)?
□ Yes
□ No Return: Did you get the customer’s signature on all warranty lines in addition to the final RO?
□ Yes
□ No FAQs: Q1: What is the issue? A1: The fuel tanks may have been improperly manufactured, resulting in a fuel leak at the seam between the tank halves. Q2: What are the affected vehicles?
A2: Certain 2022 model year Hyundai Santa Fe Plug-In Hybrid vehicles produced on April 11, 2022, through July 21, 2022, by Hyundai Motor Company (“HMC”) for sale in the U.S. market. Q3: What is the safety concern?
A3: A fuel leak in the presence of an ignition source can increase the risk of a fire. Occupants might detect a fuel smell and/or visible fuel leak associated with this condition. Q4: Have there been any accidents or injuries?
A4: As of the date of this filing (01/25/23), Hyundai has confirmed no unique incident reporting a fuel leak in the U.S. There are no confirmed crashes, injuries, or fire related to this condition. This recall was decided based on three (3) incidents occurring in Europe. Q5: Will a Stop Sale be issued?
A5: No, a stop sale will not be issued as there are no new affected vehicles in dealership inventory.
Q6: What will be done during this recall service at the dealer?
A6: All owners of the subject vehicles will be notified by first class mail with instructions to bring their vehicles to a Hyundai dealer to inspect the fuel tank and replace it, if necessary. This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty. Additionally, 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. Q7: When will owners be notified?
A7: All owners of the subject vehicles will be notified by First Class mail in late March 2023 of a remedy available. Contact Reference
Please see the following page for commonly referred to contacts. Thank you for your prompt attention to this important safety matter and continued commitment to Hyundai customers. Parts Dealer Support Contact Information
[email protected] 1-800-545-4515 Parts ordering hotline Description Techline Warranty HELPREP Line
Warranty Prior Approval (PA) Center Xtime Technical Support AutoLoop Technical Support 1‐800‐325‐6604 1‐877‐446‐2922
[email protected]
[email protected] 1‐866‐984‐6355 [email protected]
1-877-850-2010 Vehicle Technical Support for Hyundai Dealer Technicians
Warranty Claim questions for Hyundai Dealers
Warranty Prior Approval (PA) Center for Hyundai Dealers Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes
Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes CDK Technical Support Customer Support
Hyundai Customer Care Center (Recall /Campaign Questions)
Hyundai Recall /Campaign Website
Hyundai Customer Care Center (GeneralQuestions)
Hyundai Roadside Assistance https://serviceconnect.support.cdk. com/ Contact Information
1‐855‐671‐3059 www.hyundaiusa.com/recall 1‐800‐633‐5151
1-800-243-7766 Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes
Description
Customer questions or concerns related to recall or service campaigns
Updated information related to the specific recall or service campaign
Customers general questions, non‐campaign related Hyundai Roadside Assistance Key Reference Information
Name Source
Campaign Central Consolidated repository of recall and service campaign dealer best practices. Located on the service tab homepage in www.HyundaiDealer.com Car Care Scheduling (Xtime) – Tutorials
Car Care Scheduling (Xtime) – Recall Appointment Notification Parts – Campaign Parts Management (CPM) Procedure
Service Rental Car (SRC) Program Technical Service Bulletin (TSB) Uncompleted Campaign VIN Listing Recall Campaign Website NHTSAWebsite www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling 1. Log into Xtime
2. Under the menu at the top left, select ‘CONFIGURE’
3. Under the dealership tab, click “EMAIL COMMUNICATION”
4. Slide the toggle to “ADVANCED”
5. Populate as many e-mails as desired in the “PARTS DESK EMAIL FIELD”
As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management
SRC Documentation: www.HyundaiDealer.com > Service tab > Documents Library > Service Rental Car
TSD: www.HyundaiDealer.com > Service tab > SRC Fleet Mgmt Software Insurance: www.HyundaiDealer.com > Service tab > SRC Insurance www.HyundaiDealer.com > Service tab > Hyundai Tech Info
A listing of vehicles is located on WEBDCS > SERVICE tab > select UNCOMPLETED CAMPAIGN VIN LISTING
– Dealer Stock (New, SRC, CPO, etc.) and Retailed. www.hyundaiusa.com/recall
www.safercar.gov Appendix
History Date
• Recall 240: Fuel Tank Lot Code Inspection and Replacement (TSB 23-01-020H)
• Recall 240: Fuel Tank – Remedy Not Available

**************************************************************************************************************

HMA Recall 240: Fuel Tank Inspection/Replacement – Remedy Not Available –
Dealer Best Practice
January 26, 2023
Updates to this Document Date
• Recall 240: Fuel Tank – Remedy Not Available 01/26/2023
Recall Description:
The fuel tanks may have been improperly manufactured resulting in a fuel leak at the seam between the tank halves. A fuel leak in the presence of an ignition source can increase the risk of a fire. Occupants might detect a fuel smell and/or visible fuel leak associated with this condition. Affected Vehicles:
• Certain 2022MY Hyundai Santa Fe Plug-In Hybrid (TM PHEV) vehicles produced from 04/11/2022 – 07/21/2022 Remedy Information:
The remedy is currently under development and additional information will be provided once it has been developed for release. Training recommendations, if applicable, will also be made available when the remedy is ready. Recommended Alternative Transportation:
It is recommended that Service Rental Cars (SRCs) are made available for customers that are concerned with the safe operation of their vehicle prior to release of remedy. Customer Talk Tracks
“The fuel tanks may have been improperly manufactured resulting in a fuel leak at the seam between the tank halves. If this were to occur, you might detect a fuel smell and/or visible fuel leak. The fuel leak in the presence of an ignition source can increase the risk of a fire. Once a remedy is available, Hyundai will notify you via First Class mail advising you to bring your vehicle to a Hyundai dealership to have it applied at no cost to you. If you experience any of the aforementioned symptoms of the recall, please have your vehicle towed to the nearest Hyundai dealership and do not attempt to drive the vehicle until a remedy has been applied.” Best Practice Checklist:
Reservation: Did you check WebDCS for additional campaigns or recalls?
□ Yes
□ No
Reception: Did you offer the customer Alternative Transportation if requested?
□ Yes
□ No
As required by federal law, dealers must not deliver new vehicles for sale or for lease to customers until all open recalls have been performed. Dealers must 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.
To check vehicle specific recall applicability, access the “Vehicle Information” screen via WebDCS. Additional Training & Resources:
Remedy is currently under development. Applicable training courses related to this recall, if applicable, will be provided once a remedy has been released by HMA. Parts
Parts, if applicable, will be provided once a remedy has been released by HMA. Warranty
Warranty information will be updated once remedy has been released by HMA. Customer FAQs: Q1: What is the issue?
A1: The fuel tanks may have been improperly manufactured, resulting in a fuel leak at the seam between the tank halves. Q2: What are the affected vehicles?
A2: Certain 2022 model year Hyundai Santa Fe Plug-In Hybrid vehicles produced on April 11, 2022, through July 21, 2022, by Hyundai Motor Company (“HMC”) for sale in the U.S. market. Q3: What is the safety concern?
A3: A fuel leak in the presence of an ignition source can increase the risk of a fire. Occupants might detect a fuel smell and/or visible fuel leak associated with this condition. Q4: Have there been any accidents or injuries?
A4: As of the date of this filing (01/25/23), Hyundai has confirmed no unique incident reporting a fuel leak in the U.S. There are no confirmed crashes, injuries, or fire related to this condition. This recall was decided based on three (3) incidents occurring in Europe. Q5: Will a Stop Sale be issued?
A5: No, a stop sale will not be issued as there are no new affected vehicles in dealership inventory.
Q6: What will be done during this recall service at the dealer?
A6: Once an official remedy is available, 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 remedy completed free of charge, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty. 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. Q7: When will owners be notified?
A7: All owners of the subject vehicles will be notified by First Class mail in late March 2023. Contact Reference
Please see the following page for commonly referred to contacts. Thank you for your prompt attention to this important safety matter and continued commitment to Hyundai customers. Parts Dealer Support Contact Information
[email protected] 1-800-545-4515 Parts ordering hotline Description Techline Warranty HELPREP Line
Warranty Prior Approval (PA) Center Xtime Technical Support AutoLoop Technical Support CDK Technical Support Customer Support
Hyundai Customer Care Center (Recall /Campaign Questions)
Hyundai Recall /Campaign Website
Hyundai Customer Care Center (GeneralQuestions)
Hyundai Roadside Assistance 1‐800‐325‐6604 1‐877‐446‐2922
[email protected]
[email protected] 1‐866‐984‐6355 [email protected]
1-877-850-2010 https://serviceconnect.support.cdk. com/ Contact Information
1‐855‐671‐3059 www.hyundaiusa.com/recall 1‐800‐633‐5151
1-800-243-7766 Vehicle Technical Support for Hyundai Dealer Technicians
Warranty Claim questions for Hyundai Dealers
Warranty Prior Approval (PA) Center for Hyundai Dealers Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign
Integration / Operation Codes Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign
Integration / Operation Codes Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign Integration / Operation Codes
Description
Customer questions or concerns related to recall or service campaigns
Updated information related to the specific recall or service campaign
Customers general questions, non‐campaign related Hyundai Roadside Assistance Key Reference Information
Name Source
Campaign Central Consolidated repository of recall and service campaign dealer best practices. Located on the service tab homepage in www.HyundaiDealer.com Car Care Scheduling (Xtime) – Tutorials
Car Care Scheduling (Xtime) – Recall Appointment Notification Parts – Campaign Parts Management (CPM) Procedure
Service Rental Car (SRC) Program Technical Service Bulletin (TSB) Uncompleted Campaign VIN Listing Recall Campaign Website NHTSAWebsite www.HyundaiDealer.com > Service > Dealer Resources > Documents Library > Car Care Scheduling 1. Log into Xtime
2. Under the menu at the top left, select ‘CONFIGURE’
3. Under the dealership tab, click “EMAIL COMMUNICATION”
4. Slide the toggle to “ADVANCED”
5. Populate as many e-mails as desired in the “PARTS DESK EMAIL FIELD”
As applicable; www.HyundaiDealer.com > Parts > Documents Library > Campaign Parts Management
SRC Documentation: www.HyundaiDealer.com > Service tab > Documents Library > Service Rental Car
TSD: www.HyundaiDealer.com > Service tab > SRC Fleet Mgmt Software Insurance: www.HyundaiDealer.com > Service tab > SRC Insurance www.HyundaiDealer.com > Service tab > Hyundai Tech Info
A listing of vehicles is located on WEBDCS > SERVICE tab > select UNCOMPLETED CAMPAIGN VIN LISTING
– Dealer Stock (New, SRC, CPO, etc.) and Retailed. www.hyundaiusa.com/recall
www.safercar.gov Appendix
History Date
• Recall 240: Fuel Tank – Remedy Not Available 01/26/2023

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-028
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Hyundai Motor America JAN 25, 2023 NHTSA Recall No. : 23V-028 Manufacturer Recall No. : 240 Manufacturer Information :
Manufacturer Name : Hyundai Motor America Address : 10550 Talbert Avenue
Fountain Valley CA 92708
Company phone : 800-633-5151
Population :
Number of potentially involved : 326 Estimated percentage with defect : 1 %
Vehicle Information : Vehicle 1 : 2022-2022 Hyundai Santa Fe Plug-in Hybrid Vehicle Type : LIGHT VEHICLES Body Style : SUV Power Train : HYBRID ELECTRIC
Descriptive Information : Based on the suspect build range of the subject components and associated vehicle production records, the subject population includes 326 model year 2022 Hyundai Santa Fe Plug-In Hybrid vehicles produced on April 11, 2022, through July 21, 2022, by Hyundai Motor Company (“HMC”) for sale in the U.S. market.
Production Dates : APR 11, 2022 – JUL 21, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The fuel tanks may have been improperly manufactured, resulting in a fuel leak at the seam between the tank halves.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A fuel leak in the presence of an ignition source can increase the risk of a fire.
Description of the Cause : Insufficient molding caused by a malfunction of the material grinder prior to mold extrusion. Identification of Any Warning
that can Occur : Occupants might detect a fuel smell and/or visible fuel leak associated with this condition.
Involved Components : Part 573 Safety Recall Report 23V-028 Page 2 Component Name 1 : TANK ASSY-FUEL Component Description : Fuel Tank Assembly Component Part Number : 31150-P4800 Supplier Identification : Component Manufacturer
Name : TI Automotive Address : 51, 3 Gongdan 3-ro
Seobuk-gu, Cheonan-si Chungcheongnamdo Foreign States
Country : Korea, Republic of Chronology :
Please see Attachment A for the requested chronology. Description of Remedy :
Description of Remedy Program : All owners of the subject vehicles will be notified by first class mail with
instructions to bring their vehicles to a Hyundai dealer to inspect the fuel tank and replace it, if necessary. This remedy will be offered at no cost to owners for all affected vehicles, regardless of whether the affected vehicles are still covered under Hyundai’s New Vehicle Limited Warranty.
Additionally, 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. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The remedied fuel tank is produced with sufficient molding and seam integrity.
The material grinder equipment settings input by the supplier were corrected and reset upon resumption of fuel tank production on April 23, 2022. Recall Schedule :
Description of Recall Schedule : Dealers and owners will be notified in accordance with the dates listed in
this report.
Planned Dealer Notification Date : MAR 26, 2023 – MAR 26, 2023
The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-028
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573 Planned Owner Notification Date : MAR 26, 2023 – MAR 26, 2023
* NR – Not Reported

SEOCONTENT-END