Next-gen Hyundai Nexo to offer 500-mile range & V2L function [Update]

  • Next-gen Hyundai Nexo to employ a newly developed fuel cell system
  • Will deliver nearly 500 miles of range as per South Korean rating
  • Likely to feature a thoroughly updated interior with influences from the E-GMP cars
  • Expected to be launched in 2025

Update: ‘2025 Release reported’ and ‘Increased availability’ sections added and ‘Updated fuel cell system’ section revised.

Introduced in January 2018, the Hyundai Nexo was the Hyundai Motor Group’s technological marvel last decade. While HMG is planning a big wave of BEVs with the E-GMP platform, starting with the Ioniq 5, Kia EV6 & Genesis GV60, it is not losing focus of its standalone FCEV. The company plans a massive upgrade for the Hyundai Nexo, which as per SNE Research (via kedglobal), took almost 60 percent of the global FCEV market in 2022 (Jan-Aug period).

HMG will employ its upcoming third-generation fuel cell system in the new Hyundai Nexo, but it seems that the development of the car has not been without its challenges. Here’s what we know about Hyundai’s hydrogen-powered SUV:

Facelift or full model change?

Initially, HMG planned a facelifted Nexo codenamed ‘Hyundai FE PE’ to be introduced in 2023. According to a report SE Daily published on June 29, 2022, Hyundai postponed the launch of the new Nexo from 2023 to 2024. On June 14, 2023, HMG Chairman Euisun Chung announced at the Korea H2 Business Summit that the company will launch the Nexo successor in 2025.

The latest delay suggests HMG may cancel the facelift and introduce a new-generation Nexo or a new hydrogen SUV with a different name in 2025. What’s certain is that massive upgrades are in the wings, irrespective of the form of the future model (facelift, new-generation, or successor). We’ll refer to the upcoming model as the next-gen Nexo, as that makes the most sense in our opinion.

The SE Daily article suggested that the development of the third-gen hydrogen fuel cell system wasn’t up to the mark yet. It said that Hyundai didn’t see it achieving the targeted level of performance by the end of 2023, which could explain the multiple delays.

Hyundai Nexo FCV powertrain
SE Daily reports that Hyundai Motor is struggling to meet the performance expectations of its next-generation fuel cell system, which was supposed to be completed by the end of 2023. Pictured is the current Nexo FCV powertrain.

2025 Release reported

According to a report ETNews released on October 24, 2023, Hyundai recently kicked off the development of a prototype for series production of the new Nexo. The company plans to finish R&D by the end of 2024 and conduct the domestic launch in Q1 2025, followed by overseas releases in the U.S. and Europe.

Updated fuel cell system

During the Hydrogen Wave event on September 7, 2021, HMG unveiled its third-generation fuel cell system, with a plan to commercialize it in the same year as the new Hyundai Nexo and the Hyundai Staria Fuel Cell MPV – 2023. A large fuel cell SUV will follow in 2025. These timelines are quite old and should be taken with a pinch of salt, especially after the recent report from ETNews.

According to the ETNews report dated October 24, 2023, Hyundai has postponed the production of the third-generation hydrogen fuel cell system and may have canceled the plan to offer it in the new Nexo because of that. Now, it is expected to employ an updated version of the current model’s second-generation hydrogen fuel cell system. The same report also states that the company has put the Star Fuel Cell MPV on hold. Below are the originally announced improvements in the third-gen hydrogen fuel cell system, which we believe will make it to the Nexo at some point eventually:

30% smaller

There are two versions of HMG’s third-generation fuel cell stack: 100 kW and 200 kW. The 100 kW version is for passenger vehicles, and the 200 kW version is for heavy-duty vehicles. The former, which will power the new Hyundai Nexo, is 30% smaller than the second-generation stack of the Hyundai Nexo that’s currently on sale.

2023 Hyundai Nexo fuel cell system
The new Hyundai Nexo will get the 100 kW version (pictured) of Hyundai Motor Group’s third-generation fuel cell system. Image Source: Hyundai Motor Group

Compared to Nexo’s system, the 100 kW version (of the third-generation fuel cell system) is significantly smaller as we reduced its volume by 30%, which ultimately improves vehicle packaging. Compared to Nexo’s system, the 200 kW version (of the third-generation fuel cell system) is almost the same in size but with twice the output. This version was developed for commercial trucks.

Saehoon Kim, Executive Vice President and Head of Fuel Cell Center, Hyundai Motor Group (Hydrogen Wave – September 7, 2021)

The third-generation fuel cell system is still in the prototype stage, and by the time it goes into mass production, it will have more refined specifications compared to what HMG showcased at Hydrogen Wave. It will be more durable, allowing a longer vehicle lifecycle. The present-day industry standard for the durability of fuel cell stacks is 5,000 hours, which is comparable to the 10-year lifecycle of conventional passenger cars. HMG is targeting a 50-100% increase in durability for its third-generation fuel cell system. It expects the price of the fuel cell stack to be reduced by over 50% in the coming years.

More efficient

The third-generation fuel cell stack going into the next-gen Hyundai Nexo will be significantly more efficient and thus lead to an increased range. The range could be close to 500 miles, which would be a huge improvement over the current model.

In October 2020, former South Korean President Moon Jae-in visited the Hyundai Motor Group (HMG) Ulsan plant and interacted on the Hyundai Nexo with company officials. When he asked about the Nexo’s range while touring the production line that builds the powertrain, a company official said that the hydrogen fuel cell electric crossover has three hydrogen tanks and can drive 609 km (378 miles) in one go.

Adding to the employee’s response, Chung told the former President that the company plans to increase the range of the Nexo remarkably. Below were exactly his words:

I plan to increase it (Hyundai Nexo range) to 800 km (497 miles) in the future.

Euisun Chung, Chairman, Hyundai Motor Group, talking to former South Korean President Moon Jae-in at the production line of the Hyundai Nexo.

Providing a circa-500-mile range in the next-gen Hyundai Nexo, HMG would make a big statement to the world that hydrogen fuel-cell electric vehicles are undoubtedly the future beyond battery electric vehicles. Increasing the Hyundai Nexo range from 378 miles to close to 497 miles, which would be almost 500 miles, would mark a whopping 31% improvement.

Euisun Chung Moon jae-in Hyundai M.Vision S
Euisun Chung and Moon Jae-in sat in the Hyundai M.Vision S concept during their discussion about futuristic vehicles like the new Hyundai Nexo. Image sourced from the South Korean Presidential website.

In the U.S., EPA estimates that the Hyundai Nexo has a range of up to 380 miles. The hydrogen SUV has a tank capacity of 41.4 gallons. A compact 1.56 kWh Lithium-ion battery supplies during acceleration and also stores the electricity generated by the regenerative braking system. Using the electricity from the fuel cell stack and the battery, the motor spins the wheels.

500-mile FCEVs are a reality today. In Japan, the latest Toyota Mirai FCEV can travel up to approximately 850 km (WLTC) on a full tank, which converts to 528 miles.

V2L coming to the Hyundai Nexo

On April 8, 2021, an ETNews report had suggested that the next-gen Hyundai Nexo will feature V2L (Vehicle to Load) function. Hyundai Mobis, Hyundai Motor Group’s in-house parts company, has developed this technology, as per the report. “In order to secure advanced technology, we have also secured charging technology using hydrogen fuel cells,” a Hyundai Mobis official said.

V2L allows supplying the power of the vehicle’s energy source (hydrogen fuel cell in this case) to an external device, like a home appliance, for instance. It can be instrumental during disasters and emergencies when there’s a power cut. Toyota offers this feature in its hydrogen FCEV Mirai, introduced in an all-new avatar (second generation) in December 2020.

Hyundai Nexo N variant now a realistic possibility

Hyundai has indicated that hydrogen-powered cars could have an N high-performance variant. This might become possible in the new Nexo. Speaking at the Hyundai N Day on April 28, 2021, Thomas Schemera, Global Chief Marketing Officer and Head of Customer Experience Division, Hyundai, said:

Ever since we presented the hydrogen-powered N 2025 Vision Gran Turismo concept, sustainable driving fun has been N’s way of realizing Hyundai’s vision of “Progress for Humanity.” Now it’s time to make that vision become reality, no matter whether it’s battery electric or fuel cell electric or even more interestingly, a combination of both!

Thomas Schemera, Global Chief Marketing Officer and Head of Customer Experience Division, Hyundai (Hyundai N Day 2021)

Hyundai N hydrogen-electric hybrid

Schemera talked about possible alternative energy powertrains for future Hyundai N models with other company executives at the Hyundai Elantra N world premiere on July 14, 2021.

“Hydrogen, I guess, is a very interesting thing to combine and to find the right idea in the future to come,” Schemera said. In response, Albert Biermann, the former President and Head of R&D Division, Hyundai/Kia, said:

Maybe you remember our MECA proto car with the fuel cell in the front and high-power PE battery-electric system in the rear. With our modular fuel-cell system? We can make a nice package, I think.

Albert Biermann, former President and Head of R&D Division, Hyundai/Kia

Hyundai could develop its hydrogen-electric powertrain through motorsports. “We have hydrogen technology, and I think the combination, hydrogen and battery electric, E-GMP, that is a very sustainable and enjoyable N driving even in endurance racing. Let’s go for it,” Biermann said. “Way to go. Let’s make it happen,” Till Wartenberg, Vice President and Head of N Brand Management & Motorsport Sub-division, Hyundai, responded.

Revised interior

Naver user 방여남 allegedly shared spy pictures of the facelifted Hyundai Nexo. Of course, now that we are expecting a new-generation Nexo, the changes could be even more extensive.

The prototype in the images has no exterior changes, but the interior is new. Hyundai appears to have replaced the Nexo’s cockpit with that of the Ioniq 5. The test mule features the same new two-spoke steering wheel, a 12.3-inch digital instrument cluster, and a 12.3-inch HD touchscreen infotainment system. We’d like to see the bridge-type center console get cleaned up.

Hyundai Nexo Robo-taxi

Hyundai is developing a robotaxi on the basis of the Nexo hydrogen fuel-cell SUV, The Korea Herald reported on June 10, 2021. The company aims to put the Nexo robotaxi into service by the end of 2023.

A Hyundai official has revealed that the company is currently designing the hydrogen fuel-cell self-driving taxi. “The exterior currently has cameras and sensors protruding from it, so we’re working on it. The model will be ready for mass production in one to two years,” the official said.

In the U.S., Hyundai plans to make an Ioniq 5 robotaxi for the local market. Motional, a joint venture of Aptiv and Hyundai, announced on March 2021 that it would offer a modified Ioniq 5 with Level 4 autonomous driving as a robotaxi. Motional plans to provide its first robotaxi through the Lyft app starting in 2023.

Increased availability

According to the report ETNews released on October 24, 2023, Hyundai plans to manufacture 30,000 units of the new Nexo annually. Thus, we think the new Nexo could be more easily available than the current model. The company sells only around 10,000 units of the latter annually on average.

While Hyundai develops more efficient hydrogen FCEV models, Hyundai Mobis is preparing to support the product expansion by increasing fuel cell production capacity. It plans to open two new fuel cell plants in South Korea with an investment of USD 1.1 billion. Mass production at the new factories will begin in the second half of 2023, and at full capacity, they should be able to produce 100,000 hydrogen fuel cells every year. Hyundai Mobis held a groundbreaking ceremony for a new plant that will manufacture hydrogen fuel cell stacks in Incheon on October 7, 2021.

Meanwhile, in the U.S., under an agreement called Project Neptune, Hyundai has given Shell a commitment to support the expansion of its hydrogen refueling network in California by improving fuel cell vehicle sales. Shell plans to build 48 new hydrogen refueling stations and upgrade two hydrogen refueling stations in the state.

2024 Hyundai Nexo

2024 Hyundai Nexo front three quarter official image
The S.Korean-spec 2024 Hyundai Nexo is just about equipment changes to the existing, first-gen model. Image Source: Hyundai Motor Group

On June 9, 2023, the Hyundai Nexo received a yearly update in South Korea for MY2024 to keep the ball rolling until the future FCEV is ready. Just in time for summer, Hyundai has standardized After Blow in the Nexo to ensure its AC operates odor-free during hot weather. The company has added four USB-C ports (two in the front and two in the rear), rear safety power windows, and a micro antibacterial filter also to the list of standard features, on the back of customer feedback.

The 2024 Hyundai Nexo with similar minor equipment updates could arrive in the U.S. in a few months.

TopElectricSUV says

The next-gen Hyundai Nexo will likely have substantial changes all around, making what’s already one of the best hydrogen FCEVs more practical and appealing. The redesigned SUV will likely be considerably more powerful and deliver a much higher range than the outgoing model. Will it be as appealing as the U.S.-built, partly electric Honda CR-V Fuel Cell PHEV? Only time will tell.

Next-gen Hyundai Nexo FAQs

What is the next-gen Hyundai Nexo release date?

The new Hyundai Nexo could arrive in the U.S. in 2025.

What will be the next-gen Hyundai Nexo price?

The new Nexo may cost around USD 62,000 onwards.

Which models will be next-gen Hyundai Nexo rivals?

The new Hyundai Nexo will compete with the Honda CR-V Fuel Cell PHEV and Toyota Mirai.

Featured Image Source: Hyundai Motor Group