NHTSA ID Number: 11011573
Manufacturer Communication Number: PSW-WI-FSC002
TSB/Document Date: 2024-12-06
Summary
E-compressor oil cooler may have premature wear, causing oil to mix with coolant. This does not affect the performance of the oil cooler.
FIELD SERVICE CAMPAIGN
SUBJECT
E-Compressor Inspection
Campaign No.: FSC002
Issue Date: 11/07/2024
APPLICABLE MODELS/VINS
Model: MY 2024 Tre FCEV
VINs: R2393001 thru R2393042
OVERVIEW
E-compressor oil cooler may have premature wear, causing oil to mix with coolant.
PARTS REQUIRED
Qty.
Part No.
Description
As Required
PN00460048
Air Processing Unit (APU)
As Required
PN01058800
ASM – Screw Compressor
1
SN00000236
E-compressor Oil Cooler Kit
As Required
PN00459834
Pressure Protection Valve
COMMENTS
N/A
MATERIALS REQUIRED
Qty.
Part No.
Description
As Required
Commercially Available
Coolant, Valvoline® Heavy Duty Heat Transfer Fluid
As Required
Commercially Available
As Required
Commercially Available
Oil, Castrol Alphasyn T46/Chevron Cetus PAO 46
1
Commercially Available
Plug and Cap set
COMMENTS
N/A
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FIELD SERVICE CAMPAIGN
LABOR INFORMATION
Labor Operation: E-Compressor Oil Cooler and/or E-Compressor and APU Replacement
Labor Codes:
12-790564110; E-compressor oil cooler replacement
12-790560100; E-compressor replacement (If oil inspection failed)
12-798856102; APU replacement (If oil inspection failed)
12-798850102; Pressure protection valve replacement (If oil inspection failed)
Labor Times:
1.0 hours (for labor code 12-790564110)
1.0 hours (for labor code 12-790560100)
1.2 hours (for labor code 12-798856102)
0.7 hours (for labor code 12-798850102)
COMMENTS
Add labor times as required.
DISPOSITION INFORMATION
Return all affected e-compressors to:
ATTN: Tera Loew
Nikola Corporation
680 E Houser Rd
Coolidge, AZ 85128
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps
1.
Place the vehicle into Accessory or Permanent Accessory.
2. On the infotainment screen, find the “Safe Shutdown” section under Settings > SYSTEM.
Note: The Safe Shutdown section appears at the top of the SYSTEM page and will only appear when the
vehicle is in Accessory or Permanent Accessory.
3. Tap ON to select safe shutdown as shown in Figure 1.
Figure 1. Safe Shutdown
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
4. Press the START/STOP button to shut down the vehicle.
5. While the vehicle’s system is shutting down, the infotainment screen shows a notification that shutdown is in
progress as shown in Figure 2.
Figure 2. Shutdown in Progress
6. When the safe shutdown is complete, the infotainment screen will briefly show a confirmation that the MBD can
be turned off as shown in Figure 3.
Figure 3. Safe Shutdown Complete
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
Risk of damage. Before tilting the radiator and cab, the upper center front bumper trim must be removed.
Failure to follow these instructions may cause vehicle damage.
7. Lift the front grille (1) as shown in Figure 4.
8. Locate and twist the two-bumper trim (2) clips to the unlock position.
9. Remove the bumper trim (2) from the vehicle and place in a safe place.
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
Risk of damage. Before tilting the cab, the radiator must be tilted until the cab strap is fully engaged. Failure to
follow these instructions may cause vehicle damage.
10. Locate the radiator release handle (3) on the passenger side of the vehicle shown in Figure 5.
11. While holding the radiator (4) pull the handle (3).
Figure 5. Radiator Release Handles
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
12. Tilt the radiator (4) down until the cab strap (5) is fully engaged shown in Figure 6.
Figure 6. Tilting of Radiator
13. Pump the brakes in the cab to de-pressurize the rear expansion tank.
14. Tilt the cab until it is in the most forward position.
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
15. Make sure the vehicle is parked on level ground.
16. Check the diagnostics page on the infotainment center for any HVAC related faults.
17. Use the manual battery disconnect (MBD) to disconnect the vehicle’s electrical system as shown in Figure 7.
Figure 7. Manual Battery Disconnect Off
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FIELD SERVICE CAMPAIGN
PROCEDURE
Preliminary Steps Cont.
18. Remove the left and right bottom rear plates (A) on the back side of the backpack by turning the two fasteners (1)
on each panel one quarter turn as shown in Figure 8.
19. Remove the center lower panel (B) from the backpack by removing nine screws (2).
Figure 8. Lower Backpack Rear Panels Removal
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FIELD SERVICE CAMPAIGN
PROCEDURE
Inspection of Oil in the Electronics Coolant Tank
1.
Do a visual inspection of the electronics expansion tank as follows:
a. If there is no evidence of oil in the electronics expansion tank as shown in Figure 9, refer to
Replacement of the E-Compressor Oil Cooler.
Figure 9. No Oil in Coolant Tank
b. If there is oil in the electronics expansion tank as shown in Figure 10, refer to
Replacement of E-Compressor and APU.
Figure 10. Oil in Coolant Tank
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FIELD SERVICE CAMPAIGN
PROCEDURE
Inspection of Coolant in the APU
1.
Open the APU filter to see if there is coolant present as follows:
a. If coolant is not present in the APU filter, refer to Replacement of the E-Compressor Oil Cooler.
b. If coolant is present on the exhaust port and inside the APU filter as shown in Figure 11, then refer to
Replacement of E-Compressor and APU.
Figure 11. Coolant Present on Exhaust Port and Inside APU Filter
2. Check the primary/secondary/ECAS 5L air tank to see if coolant is present as follows:
a. If no coolant is present in the tanks, clean the delivery lines before the tanks to compressor, then refer to
Replacement of E-Compressor and APU.
b. If coolant is present in the tanks, notify the Pulse team.
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of the E-Compressor Oil Cooler
1.
Pull all five Bowden cables to de-pressurize the pneumatic system.
2. Vent the pneumatic system entirely by unscrewing the filling plug for one turn as shown in Figure 12.
3. Wait until the pressure is entirely released.
4. Unscrew and remove the filling plug.
Figure 12. Filling Plug Removal
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of the E-Compressor Oil Cooler Cont.
5. Remove the oil filter cover (1) and remove the oil filter (2) from the e-compressor as shown in Figure 13.
6. Remove the input hose (3) on the e-compressor oil cooler by removing the hose clamp (4).
NOTE: The clamp stays with the hose.
7. Have a shop rag ready to capture coolant, then put a plug and cap on the hose.
8. Remove the output coolant hose (5) from the oil cooler with the quick disconnect connector (6).
9. Have a shop rag ready to capture coolant, then put a plug and cap on the hose.
Figure 13. Oil Cooler Hoses and Oil Filter on E-Compressor Removal
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of the E-Compressor Oil Cooler Cont.
10. Remove and discard the oil cooler bolt (3), sealing washer (2), and oil cooler (1) from the e-compressor as shown in
Figure 14.
11. Place the new oil cooler (1) into position onto the e-compressor, parallel to the housing with the coolant
connections facing up.
12. Install the new sealing washer (2) and new oil cooler bolt (3) to the new oil cooler (1).
13. Use a torque wrench to torque the new oil cooler bolt (3) to 29.5 ± 3.0 lb-ft (40 ± 4 N·m).
Figure 14. E-Compressor Oil Cooler Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of the E-Compressor Oil Cooler Cont.
14. Remove the plug and cap from the output coolant hose (5) and reconnect the hose on the oil cooler output with
the quick disconnect connector (6) as shown in Figure 15.
15. Remove the plug and cap from the input coolant hose (3) and reconnect the hose to the oil cooler with the hose
clamp (4).
16. Reinstall the oil filter (2) on the e-compressor, then install the oil filter cover (1) on the oil filter (2).
Figure 15. Oil Cooler Hoses and Oil Filter on E-Compressor Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of the E-Compressor Oil Cooler Cont.
17. Visually check for the oil level to be at the bottom of the threads in the port (normal oil level) as shown in Figure 16.
18. Slowly fill oil into the port until oil starts to slowly leak out and settles.
NOTE: Refer to “MATERIALS REQUIRED“ on page 1 for correct oil.
19. Screw in the filling plug and torque to 29.5 ± 3.0 lb-ft (40 ± 4 N·m).
Figure 16. Filling Plug Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU
1.
Depressurize the compressed air system by pulling the five bowden cables.
High voltage. Death or severe injury to personnel could occur. Deactivate the high-voltage system before
working on the e-compressor.
2. De-energize the high-voltage electrical system.
3. Drain the oil and coolant from the electronics expansion tank.
4. Remove the output coolant hose (1) on the oil cooler with the quick disconnect connector (2) as shown in
Figure 17.
5. Have a shop rag ready to capture coolant, then put a plug and cap on the hose (1).
6. Remove the input coolant hose (3) on the e-compressor with the quick disconnect connector (4).
7. Have a shop rag ready to capture coolant, then put a plug and cap on the hose (3).
Figure 17. Input and Output Coolant Hose Removal
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU Cont.
8. Remove the hard aluminum line (1) from under the oil filter to the pressure protection valve (5) by disconnecting
two clamps (2) and two nuts (3) as shown in Figure 18.
9. Clean the inside of the aluminum line (1) with isopropyl alcohol.
10. Disconnect the flexible hose (4) that goes from the APU to the pressure protection valve (5) by disconnecting
nut (6).
11. Disconnect the high voltage and low voltage connectors from the e-compressor.
12. Remove four bolts (7) , then remove the e-compressor (8) from the vehicle.
13. Remove and discard the pressure protection valve (5) by disconnecting the nut (9).
Figure 18. E-Compressor and Pressure Protection Valve Removal
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU Cont.
14. Disconnect all pneumatic lines (1) on the APU. See Figure 19.
15. Cut all cable ties (2) from the APU.
16. Remove bolt and nut (3) from the APU fixation bracket.
17. Remove bolt (4) from the APU fixation bracket (7).
18. Remove two bolts (5) from the APU fixation bracket (7).
19. Remove the APU with APU fixation bracket (7) from the vehicle.
20. Remove the APU fixation bracket (7) from the APU by removing three hex bolts (6).
21. Disconnect the hose (8) from the APU with nut (9).
22. Discard the APU.
23. Clean the inside of the hose (8) and the flexible hose line connected to it with isopropyl alcohol.
24. Reconnect the hose (8) along with the flexible hose line to the new APU with nut (9).
25. Torque the nut (9) to 59 ± 5.9 lb-ft (80 ± 8 N·m).
26. Install the APU fixation bracket (7) on the new APU with three hex bolts (6).
27. Torque the three hex bolts (6) to 51.6 ± 8.1 lb-ft (70 ± 11 N·m).
28. Place the new APU with the APU fixation bracket (7) on the vehicle.
29. Install two bolts (5) on the APU fixation bracket (7).
30. Install bolt (4) on the APU fixation bracket (7).
31. Install bolt and nut (3) to the APU fixation bracket (7).
32. Torque the two bolts (5) to 42 ± 6.6 lb-ft (57 ± 9 N·m).
33. Torque the bolt (4) to 42 ± 6.6 lb-ft (57 ± 9 N·m).
34. Torque the nut (3) to 22.1 ± 3.0 lb-ft (30 ± 4 N·m).
35. Install new cable ties (2) to the APU.
36. Connect all pneumatic lines (1) on the APU.
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU Cont.
Figure 19. APU Removal and Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU Cont.
37. Connect the new pressure protection valve (5) to bracket with nut (9) as shown in Figure 20.
38. Connect the flexible hose (4) that goes from the APU to the protection valve (5) with nut (6).
39. Torque the nuts (6 and 9) to 59 ± 5.9 lb-ft (80 ± 8 N·m).
40. Install the new e-compressor (8) on the vehicle with four bolts (7).
41. Torque the four bolts (7) to 29.5 ± 3.0 lb-ft (40 ± 4 N·m).
42. Reconnect the aluminum line (1) from under the oil filter to the pressure protection valve with two nuts (3) and two
clamps (2).
43. Torque the two nuts (3) to 59 ± 5.9 lb-ft (80 ± 8 N·m).
Figure 20. E-Compressor and Pressure Protection Valve Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Replacement of E-Compressor and APU Cont.
44. Connect the high voltage and low voltage connectors to the e-compressor.
45. Remove the plug and cap from the output coolant hose (1) and reconnect the hose to the oil cooler output with the
quick disconnect connector (2) as shown in Figure 21.
46. Remove the plug and cap from the input coolant hose (3) and reconnect the hose to the e-compressor with the
quick disconnect connector (4).
47. Slowly fill oil into the port until oil starts to slowly leak out and settles.
NOTE: Refer to “MATERIALS REQUIRED“ on page 1 for correct oil.
48. Add coolant to the electronics expansion tank until the level is at the MAX line.
NOTE: Refer to “MATERIALS REQUIRED“ on page 1 for correct coolant.
Figure 21. Input and Output Coolant Hose Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Final Steps
1.
Install the center lower panel (B) to the backpack with nine screws (2) as shown in Figure 22.
2. Torque the nine screws (2) to 177 ± 17.7 lb-in (20 ± 2 N·m).
3. Install the left and right bottom rear plates (A) on the back side of the backpack by turning the
two fasteners (1) on each panel one quarter turn.
Figure 22. Lower Backpack Rear Panels Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Final Steps Cont.
4. Tilt the cab back to its original position if needed.
5. Push the radiator (1) back until it locks into the place shown in Figure 23.
Figure 23. Radiator Lock Position
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FIELD SERVICE CAMPAIGN
PROCEDURE
Final Steps Cont.
6. Reinstall the bumper trim (2) onto the vehicle shown in Figure 24.
7. Locate and twist the two bumper trim (2) clips to the lock position.
8. Lower the front grille (1) on the vehicle.
Figure 24. Bumper Trim Installation
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FIELD SERVICE CAMPAIGN
PROCEDURE
Final Steps Cont.
9. Turn the MBD switch to the ON position shown in Figure 25.
Figure 25. Manual Battery Disconnect On
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- Contains Alugard Plus for compatibility with all ethylene...
- Fights corrosion, scaling and rust while protecting all...
- High-quality additives protect against leaks and won’t...
- Pre-mixed yellow formula is ready-to-use in a 50/50 ratio...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
- 5 year/150, 000 mile . Silicate-free, long-life, phosphate...
- Formulated to replace the OEM fluid in Asian make vehicles...
- The long life formula provides protection for all cooling...
- Meets the following OEM and industry specifications...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
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TSB/Document ID: PSW-WI-FSC002
Replacement Service Bulletin Number:
MFR Communication Date: 2024-11-08
MFR Internal Campaign ID/Software Version: PSW-WI-FSC002
Communication Type: Service Campaign
NHTSA Components: SERVICE BRAKES
MFR Component System:
MFR Component Subsystem:
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