Service Campaign 9B3: Exhaust Gas Recirculation (EGR) Valve Assembly & Gasket
Replacement – Dealer Best Practice
September 25, 2024
Document Topic
• Technical Service Bulletin (TSB) 24-01-080H published

Date
09/25/2024

Description of Campaign
The exhaust gas recirculation (EGR) valve assembly in certain vehicles may contain a sensor that was
contaminated with solder flux during manufacturing, which could potentially result in an electrical short. An
electrical short within the EGR valve could lead to a Malfunction Indicator lamp (MIL) illumination (P0405,
P0642, P0652, P0404/P049D/P240F).
The California Air Resources Board has determined that these vehicles may be releasing air pollutants which
exceed Federal and California standards.

Affected Vehicles (Certain)
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2024MY Tucson (NX4) equipped with Theta 2.5 GDI and produced 01/17/2024 – 02/22/2024
2024MY Sonata (DN8) equipped with Theta 2.5 GDI and produced 02/06/2024 – 02/16/2024
2024MY Sonata Hybrid (DN8 HEV) equipped with Nu 2.0 GDI and produced 02/06/2024 – 02/24/2024

Repair Process/Information
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Refer to TSB 24-01-080H (or latest version) for replacement of the EGR valve assembly & gasket.
Technician Certification Requirements: Hyundai Expert (or higher) is required.

Recommended Alternative Transportation
A Service Rental Vehicle (SRC) should be provided to customers if their vehicle requires to be kept overnight. In
addition, a SRC may be required based on the repair procedure duration and any other additional work on the
vehicle that may need to be addressed during customer’s visit. If a SRC is not available, other options such as a
3rd Party Rental or Rideshare may be provided.

Service Tips/Training
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If a customer arrives to the dealer with no appointment scheduled, it is recommended for the dealer to
offer alternative transportation to the customer.
If customer schedules an appointment in advance, ensure the appropriate parts, equipment, and tools
are on hand to perform any related repairs.
Always inquire if the customer will have time for an additional service to be performed if they were
originally scheduled for a different service.
All vehicles will require replacement of the EGR valve & gaskets are 100%.
Every vehicle needs to have an emission sticker under the hood included after the inspection.
A proof of correction card will also need to be provided to affected vehicles in certain states. Please
refer to TSB for applicable states.
Offer SRC assistance for customers who may be pressed on time.
Be honest with customers on wait times.
If the service is taking longer than expected, update the customer.
If you are unsure of certain processes, don’t guess. Take time to familiarize yourself with the proper
procedures or ask for help/clarity from your teammates or leadership.
If you see a team member having trouble addressing the concern, ask if you can provide some help.

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Warranty Information
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Per TSB 24-01-080H (or latest version), this service campaign pays the following:
o Labor:
 0.5 M/H for replacement of the EGR Valve Assembly/Gasket Replacement (Sonata Hybrid
ONLY)
 2.4 M/H for replacement of the EGR Valve Assembly/Gasket Replacement (Sonata ONLY)
 2.5 M/H for replacement of the EGR Valve Assembly/Gasket Replacement (Tucson ONLY)
o Parts:
 Dealer will be reimbursed for the EGR valve assembly and EGR pipe (all models).
 For Tucson/Sonata ONLY – dealer will also be reimbursed for the following:
• Crankshaft position Sensor (CKPS)
• EGR Service Kit
• Coolant (QTY: 5 quarts if Sonata, 6 if Tucson)
Photos: The time above includes taking a picture as noted below.
o Taking a photo of the newly installed EGR valve capturing the production stamp with the last 6
digits of the VIN and the date of repair on a piece of paper.

Parts Information
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Refer to TSB 24-01-080H (or latest version) for the complete list of required parts.
o The following parts numbers will require a valid campaign 9B3 VIN to order the part:
 28400-2J310QQH
 28400-2S000QQH
 28492-2J000QQH
 28493-2S040QQH
 28751-2S001QQH
 28751-2S002QQH
 28493-2S030QQH
 39180-2S000QQH
Vehicle Emission – Proof of Correction Card (NP050-09006): Dealers from certain states referred to in
‘Remarks’ section are required to provide a card to customers as proof of the vehicle completing the
campaign.
Part Name

Part Number

Qty

Figure

Remarks

9B3
Campaign Sticker

NP001-SC9B3

Apply to all vehicles
regardless of state.

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NP001-SC9B3

Vehicle Emission
Recall - Proof of
Correction Card

NP050-09006

Order only for states:
CA, CO, CT, DE, ME,
MD, MA, NJ, NY, OR,
PA, RI, VT, WA

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Customer Talk Tracks
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For customers with an appointment, but campaign not part of originally scheduled services: “I see that
your vehicle has an open service campaign that we would like to take care of for you while you are here
today. This service campaign requires the vehicle’s exhaust gas recirculation valve assembly and gasket
needs to be replaced to avoid a potential electrical short or malfunction. This service, of course, will be
provided at no charge to you and, if necessary, we would like to offer you alternative transportation while
we repair your vehicle. We apologize for the inconvenience.”

2. For Walk-In Customers: “During your visit today, I checked your vehicle for any open campaign or recalls
and found that your vehicle has an open campaign. This service campaign requires the vehicle’s exhaust
gas recirculation valve assembly and gasket needs to be replaced to avoid a potential electrical short or
malfunction. This service, of course, will be provided at no charge to you and, if necessary, we would like to
offer you alternative transportation while we repair your vehicle. We apologize for the inconvenience.”
3. For customers over the phone: “While I have you on the line and verifying your current appointment, I ran
your VIN and see that your vehicle has an open campaign. This service campaign requires vehicle’s exhaust
gas recirculation valve assembly and gasket needs to be replaced to avoid a potential electrical short or
malfunction. If time permits, we can address this campaign during your current appointment, and it will be
at no cost to you. Should you need, we can arrange for alternate transportation since this may prolong the
stay of your vehicle at service. We apologize for the inconvenience.”

Best Practice Checklist
Reservation: Did you check WebDCS for additional campaigns or recalls? Did you check for any decline
services from previous visits?
Yes
No – Please ensure all open campaign(s)/recall(s) are identified and completed by the dealership.
Also ask customer if he/she would like to have any of the previous declined services performed.
Readiness: Are parts in stock to complete this campaign?
Yes
No – Please order the parts from your corresponding PDC as necessary. If possible, place order
ahead of time if customer has made an appointment in advance.
Reception: Did you explain to the customer the expected repair time and an expectation for a status
update?
Yes
No – Customer should be given an estimated time of when his/her vehicle is completed so the
customer can plan the rest of their day away from the dealership.
Did the customer provide authorization to perform repairs?
Yes
No – Customer must be consulted and provide approval before proceeding with any repairs on
their vehicle.
Did you offer the customer Alternative Transportation if requested?
Yes
No – Customer should be offered alternative transportation if they feel uncomfortable in the
operation of their vehicle prior to the repair being completed on his/her vehicle. In addition, a SRC
may be required based on the repair procedure duration and any other additional work on the
vehicle that may need to be addressed during customer’s visit.
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Repair: Does the Technician meet the recommended training requirements (Expert level or above) to
complete this campaign?
Yes
No – Please ensure a technician with a Hyundai Expert (or higher) completes this repair.
Return: Did you get the customer’s signature on all warranty lines in addition to the final RO?
Yes
No

Customer FAQs
Q1: What is the issue?
A1: The exhaust gas recirculation (“EGR”) valve assembly in certain Hyundai vehicles may contain a sensor that
was contaminated with solder flux during manufacturing, which could potentially result in an electrical short. An
electrical short within the EGR valve could lead to a malfunction of the EGR valve or crank position sensor, both
of which reside on the same power circuit, resulting in Malfunction Indicator Lamp illumination (P0405, P0642,
P0652, P0404/P049D/P240F).
Q2: What are the affected vehicles?
A2: Affected vehicle model/model years include the following:
• 2024-25MY Tucson (NX4) equipped with Theta 2.5 GDI and produced 01/17/2024 – 02/22/2024
• 2024-25MY Sonata (DN8) equipped with Theta 2.5 GDI and produced 02/06/2024 – 02/16/2024
• 2024-25MY Sonata Hybrid (DN8 HEV) equipped with Nu 2.0 GDI and produced 02/06/2024 –
02/24/2024
Q3: Why is this campaign being provided to me?
These vehicles may be releasing air pollutants which exceed Federal and California standards. These standards
were established to protect your health and welfare from the dangers of air pollution.
Q4: Are you a California registered owner or one from Colorado, Connecticut, Delaware, Maine, Maryland,
Massachusetts, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont or Washington?
A4: Because your state has adopted the California emissions regulation, your Hyundai dealer will also provide a
“Proof of Correction” certificate as verification that this repair has been completed. It’s critical that it is retained
for your records and to be presented when registering your vehicle, if requested.
Q5: What if the repair is not completed?
A5: Failure to have this service performed could cause your vehicle to fail an emissions inspection (SMOG
check) when required under state law. It could also be considered a lack of proper maintenance.
Q6: What will be done during service at the dealer?
A6: The service procedure requires replacing the EGR valve(s) and gasket(s).
Q7: When will affected customer(s) be notified of this campaign?
A7: Customers will be notified via First Class Mail in October 2024.

Contact Reference
Please see the following list of commonly referred to contacts. Thank you for your prompt attention to this
important emissions matter and continued commitment to Hyundai customers.

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Directions for Proof of Emissions Card

NOTE: This step is only for vehicles registered in California, Colorado, Connecticut, Delaware, Maine,
Maryland, Massachusetts, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont, and
Washington:
The completed card must be given to the vehicle owner upon Campaign completion.
VEHICLE EMISSION RECALL - PROOF OF CORRECTION CARD
A Vehicle Emission Recall - Proof of Correction card must be filled out for all vehicles registered in California,
Colorado, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Jersey, New York, Oregon,
Pennsylvania, Rhode Island, Vermont, and Washington. Residents of these states, who own an affected
vehicle, will be required to possess a Vehicle Emission Recall - Proof of Correction card as evidence of
voluntary service campaign completion, when they apply for vehicle registration renewal.
WHAT TO DO WITH THE CARD:
The Vehicle Emission Recall - Proof of Correction card must be completed by the Dealership’s Service Manager
using a permanent ink pen. A fine point pen is recommended. When filling in the information, copy the
information directly from the vehicle, not from the repair order.
ALL INFORMATION MUST BE PRINTED AND NEAT.
The completely filled out Vehicle Emission Recall - Proof of
Correction card should be given to the owner of the vehicle upon
completion of the Campaign.
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7. Enter Dealership Name
8. Enter Dealership’s Address
NOTE: Enter the physical address,
not the mailing address (not a P.O.
Box)
9. Enter Date of Repair
10. Service Manager Sign Here

Enter Vehicle’s License Number
Enter “Hyundai”
Enter Model Year
Enter “Santa Fe”
Enter the vehicle’s VIN Number
Enter “9B2”

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Key Contact Information
Dealer Support
Parts

Contact Information

Description

[email protected]

Parts ordering hotline

1-800-545-4515
Techline

1‐800‐325‐6604

Warranty HELP Line

1‐877‐446‐2922

Vehicle Technical Support for Hyundai Dealer
Technicians
Warranty Claim questions for Hyundai Dealers

Warranty Prior Approval (PA) Center

[email protected]

Warranty Prior Approval (PA) Center for Hyundai Dealers

[email protected]
1‐866‐984‐6355

Assistance with Car Care Scheduling:
• Appointment / Shop Capacity Management / Campaign
Integration / Operation Codes

[email protected]

Assistance with Car Care Scheduling:

Xtime Technical Support

AutoLoop Technical Support

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1-877-850-2010

CDK Technical Support

Appointment / Shop Capacity Management / Campaign
Integration / Operation Codes

https://serviceconnect.support.cdk.com/ Assistance with Car Care Scheduling:

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Customer Support

Appointment / Shop Capacity Management / Campaign
Integration / Operation Codes

Contact Information

Description

Hyundai Customer Care Center
(Recall /Campaign Questions)

1‐855‐671‐3059

Customer questions or concerns related to recall or service
campaigns

Hyundai Recall /Campaign Website

www.hyundaiusa.com/recall

Updated information related to the specific recall or service
campaign

Hyundai Customer Care
Center(GeneralQuestions)

1‐800‐633‐5151

Hyundai Roadside Assistance

1-800-243-7766

Customers general questions, non‐campaign related
Hyundai Roadside Assistance
Key Reference Information

Name
Campaign Central

Source
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 www.HyundaiDealer.com > Service > Dealer Resources > DocumentsLibrary > Car Care Scheduling
Car Care Scheduling (Xtime) - Recall
Appointment Notification

Parts – Campaign Parts Management
(CPM) Procedure
Service Rental Car (SRC) Program

1.
2.
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5.

Log into Xtime
Under the menu at the top left, select ‘CONFIGURE’
Under the dealership tab, click “EMAIL COMMUNICATION”
Slide the toggle to “ADVANCED”
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

Technical Service Bulletin (TSB)

www.HyundaiDealer.com > Service tab > Hyundai Tech Info

Uncompleted Campaign VIN Listing

A listing of vehicles is located on WEBDCS > SERVICE tab > select UNCOMPLETED CAMPAIGN VIN LISTING
– Dealer Stock (New, SRC, CPO, etc.) and Retailed.

Recall Campaign Website

www.hyundaiusa.com/recall

NHTSA Website

www.safercar.gov

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