AASJ0 Restricted Fuel Pickup Tube May Cause Engine Stall – 2022-2023 Hino NE7A, NJ7A, NJ7B, & NV7A

December 6, 2022 NHTSA CAMPAIGN NUMBER: 22V898000

Restricted Fuel Pickup Tube May Cause Engine Stall

Restricted fuel update can cause an engine stall, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V898000

Manufacturer Hino Motors Sales U.S.A., Inc.

Components FUEL SYSTEM, DIESEL

Potential Number of Units Affected 970

 

Summary

Hino Motors Sales U.S.A., Inc. (Hino) is recalling certain 2022-2023 NE7A, NJ7A, NJ7B, and NV7A vehicles equipped with a 50-gallon fuel tank. The fuel pickup tube may contact the bottom of the tank, restricting the uptake of fuel to the engine.

 

Remedy

Dealers will replace the fuel tube, free of charge. Owner notification letters were mailed on January 19, 2023. Owners may contact Hino’s customer service at 1-248-699-9390. Hino’s number for this recall is AASJ0.

 

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.

 


RECALL NO: AASJ0
DATE: 12-7-2022
REFERENCE: QA-221207-N1

SUBJECT VEHICLES: Certain 2022 and 2023 model year

Conventional trucks equipped with a 50 gallon fuel tank produced at the Mineral Wells, WV assembly plant between October 21, 2021 and October 12, 2022.

Note: Refer to the appropriate Vehicle Identification Number in the warranty system to determine vehicle eligibility.

 

OVERVIEW:

The fuel pickup tube installed into certain 50-gallon fuel tanks may bottom out, restricting the uptake of fuel to the engine. This procedure will provide the instruction to measure the fuel pickup tube and based on the result, either cut the tip or replace the pickup tube to ensure correct clearance with the bottom of the fuel tank.

 

PARTS:

Part NumberDescriptionQuantity
SZ17712005Hex Nut, W/Plastic Insert2
7013076200Fuel Pick Up Tube1 (As Needed)
023015 (Harvey #)Harvey TFE Paste (locally sourced)

 

VEHICLE PREPARATION:

  1. Park the vehicle on a level and solid surface. Confirm the engine is stopped, the starter switch is in the off (LOCK) position, and the key is removed.
  2. Apply the parking brake. Chock all of the wheels.

 

REPAIR PROCEDURE:

  1. Remove the six bolts attaching the lower cab step and remove the step. Retain the 6 bolts and lower step for reassembly.
  2. Remove the ten bolts attaching the upper cab step and remove the step. Retain the 10 bolts and upper step for reassembly.
  3. Disconnect the fuel level sending unit electrical connection.
  4. Remove the locking ring from the fuel pick up tube at the rear of the fuel tank. Carefully spread the open end of the clip and slide it off the connection. Wrap a rag around the fuel line and lift the fuel line from the fitting.
  5. Remove the two nuts securing the fuel tank straps to the fuel tank mounting brackets. Discard these nuts, they will not be reused. Protect the underside of the cab with a cloth and lift the fuel tank straps upwards and away from the fuel tank.
  6. Slide the fuel tank rearward on the chassis until the fuel pick up tube on the rear of the tank clears the rear edge of the cab.

Notice: Care should be taken to prevent damaging the fuel tank or cab.

  1. Remove the fuel pick up tube from the fuel tank.
  2. Measure the fuel pick up tube from the top of the fitting and mark the tube at 20-15/16inches or 532mm. Cut the tube at this mark using a tubing cutter. If the tube is shorter than this measurement, replace the tube with a new 7013076200 fuel pick up tube. Mark and cut the new fuel pick up tube to the proper dimension.

NOTICE: Do not use wire cutters to cut the tube as damage to the tube will occur.

  1. Apply a thin coating of TFE paste to the threads of the fuel pick up tube fitting. Use care as to not allow excess paste under the threaded portion as this can contaminate the fuel tank.
  2. Install the fuel pick up tube in the fuel tank and tighten to the specified torque.

Specified Torque: 25 lb-ft (34 Nm)

  1. Return the fuel tank to its original location. Confirm the locating tabs on the inside of the tank are positioned around the rear tank bracket correctly.
  2. Reposition the two fuel tank straps and install a new SZ17712005 nut on each strap. Do not tighten the nuts at this time.
  3. Reconnect the fuel level sending unit electrical connection.
  4. Reconnect the fuel pick up line by pushing the line back into the pick up tube on the fuel tank. Slide the locking ring removed in step 4 around the connection and ensure it is fully seated.
  5. Reinstall the upper cab step and all ten fasteners removed in step Tighten the fasteners to the specified torque.

Specified Torque: 32 lb-ft (43 Nm)

  1. Reinstall the lower cab step and all six fasteners removed in step Tighten the fasteners to the specified torque.

Specified Torque: 32 lb-ft (43 Nm)

  1. Tighten the two fuel tank strap nuts to the specified torque.

Specified Torque: 19 lb-ft (26 Nm)

 

FINAL INSPECTION:

  1. To complete this procedure, review the recall and confirm the following:
  • The fuel pick up tube has been cut to the correct length.
  • The fuel pick up tube has been properly resealed.
  • All fasteners have been tightened to the specified torque.
  • Any fuel spillage has been wiped from the outside of the fuel tank.

 

 


1. Chronology of Defect Determination

August, 2022
In the first half of August, 2022, Hino received four field reports from a dealer regarding vehicles equipped with 50-gallon fuel tanks with a low fuel pressure MIL illuminated. The dealer reported that upon inspection they observed the pickup tube in the fuel tank was bottomed out and likely caused a fuel flow restriction.

September, 2022
Beginning in early September, Hino began proactive inspections of fuel tanks in inventory which had not yet been installed on any vehicles. The inspections showed that some 50-gallon fuel tanks were slightly deformed and the clearance between tip of the pickup tube and bottom of the fuel tank was below minimum designed tolerance.

On September 14, based on the results of above-referenced inspection, Hino issued a shipping suspension at its WV assembly plant and decided to continue to investigate fuel pickup tube clearance in 50-gallon tanks and consider possible countermeasures for this issue.

In late September, Hino initiated an audit at the WV assembly plant to confirm the clearance between the tip of the pickup tube and the bottom of fuel tanks already installed on vehicles in its inventory.

As of September 20, as the result of the audit, Hino determined that approximately sixty percent of inventory vehicles equipped with 50-gallon fuel tanks had fuel pickup tubes that were under the minimum designed tolerance for clearance with the bottom of the fuel tank. Despite being outside tolerance, however, none of these vehicles demonstrated complete blockage of the pickup tube; the low pressure MIL present in field reports; or any indication that engine power had reduced because of lack of fuel.

At the end of September, Hino invited its supplier to observe and discuss the 50-gallon fuel tank installation process. This process revealed that in some instances installation of the 50-gallon fuel tank caused it to flex and bow inward, reducing fuel pickup tube clearance.

October – November, 2022
On October 13, based on the result of the inventory vehicle audit and several joint inspections with the supplier, Hino started inspecting fuel pickup tube clearances during the vehicle production process at the WV plant. Where the clearance was too small, Hino adjusted the fuel pickup tube to be within the design tolerance for clearance with the bottom of the fuel tank.
Hino began duplication testing with a modified tank with no pickup tube clearance. As a result of the test, Hino observed that low engine power or engine stall may occur in the worst case scenario, i.e., when the fuel pickup tube has zero clearance and has completely bottomed out against the bottom of the fuel tank. Even then, stalling would occur only under certain high load driving conditions. None of Hino’s inspections to date have revealed this worst case scenario.

As of the end of November, Hino is still continuing further investigation to clarify the cause of deformation of 50- gallon fuel tanks.

On November 29, 2022, out of abundance of caution, based on the results of the above-referenced investigation and field reports, Hino determined to conduct a voluntary safety recall campaign for the subject vehicles equipped with a 50-gallon fuel tank.

As of November 23, 2022, Hino is aware of four field reports alleging low engine power, received in August 2022. Hino has also investigated warranty claims for fuel tank repairs. As of November 23, 2022, Hino is aware of twenty-two warranty claims for fuel tank repairs, including the four field reports just mentioned, involving a MIL illuminated for low fuel pressure. The repairs occurred between July 17, 2022 and September 19, 2022. Hino has used this figure to approximate the number of potentially affected vehicles. These warranty claims included eight instances of engine stalling. Hino has not yet had the opportunity to inspect any of vehicles associated with the reports of engine stalling, Hino is not aware of any reports of accidents or injuries resulting from reduced fuel pickup tube clearance.

 


8 Affected Products

Vehicles

MAKEMODELYEAR
HINONE7A2022-2023
HINONJ7A2022-2023
HINONJ7B2022-2023
HINONV7A2022-2023

 


9 Associated Documents

Recall Acknowledgement

RCAK-22V898-4517.pdf 646.037KB

 


Miscellaneous Document- Chronology

RMISC-22V898-1523.pdf 105.545KB

 


Defect Notice 573 Report

RCLRPT-22V898-6419.PDF 214.16KB

 


Recall 573 Report-Amendment 1 – 01/09/2023

RCLRPT-22V898-6441.PDF 214.209KB

 


Remedy Instructions and TSB

RCRIT-22V898-0664.pdf 874.895KB

 


Part 577 Owner Notification Envelope

RONE-22V898-8961.pdf 101.294KB

 


Owner Notification Letter(Part 577)

RCONL-22V898-5559.pdf 166.139KB

 


Recall Quarterly Report #1, 2023-1

RCLQRT-22V898-8751.PDF 211.149KB

 


Recall Quarterly Report #2, 2023-2

RCLQRT-22V898-8307.PDF 211.253KB

 


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